Gehl R105 (EU), R105, R105 X-Series Operator's Manual

R105

R105 (EU)

R105 X-SERIES

SKID-STEER LOADERS

Form No.

50950260/

AP1216

English

Operator’s Manual

Manitou Americas, Inc., in
cooperation with the American

Society of Agricultural Engineers
and the Society of Automotive
Engineers, has adopted this Safety Alert
Symbol to pinpoint precautions which, if
not properly followed, can create a
safety hazard. When you see this symbol
in this manual or on the machine itself,
you are reminded to BE ALERT! Your
personal safety is involved!

Operators must have instructions
before running the machine.
Untrained operators can cause
injury or death.

CORRECT

WRONG

Never use loader
without ROPS/FOPS.
Never modify the
ROPS/FOPS
structure.

WRONG

Read Operator’s Manual
before using machine.

CORRECT

Always fasten seatbelt
snugly. Always keep feet on
the floor/pedals when
operating loader.

Never use the loader
to lift personnel.

WRONG

Do not use loader
around explosive dust
or gas, or where
exhaust can contact
flammable material.

R105 Skid-Steer Loader Operator’s Manual

TABLE OF CONTENTS

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Controls and Safety Equipment . . . . . . . . . . . . . . . . . . . 17

Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85

Maintenance Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . 97

Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101

Table of Common Materials and Densities. . . . . . . . . . 105

Torque Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . 107

Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108

Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109

Loader Model Number
Loader Serial Number
Engine Serial Number

All-Tach™ and Hydraloc™ are trademarks of Manitou Americas, Inc.

®

and Powerview® are registered trademarks of Manitou Americas, Inc.

Gehl

EC DECLARATION OF CONFORMITY

1. Manufacturer: Manitou Americas, Inc.

2. Address: One Gehl Way

West Bend, WI 53095-0179 U.S.A.

3. Technical Construction File Location:

4. Authorized Representative:

5. Address:

6. We hereby declare that the model(s) listed below

conforms to EC Directives: 2004/108/EC (EMC),
97/23/EC (Pressure Equipment), 2006/42/EC
(Machinery) and 2000/14/EC (Noise Emission), as
amended by 2005/88/EC.

7. In accordance with EN/ISO Standards:

EN ISO 3450:1996, ISO 6165

8. Category: EARTH-MOVING MACHINERY/
LOADERS/COMPACT

9. Model(s): 

10. Directive/Conformity Assessment Procedure/Notified Body:

2004/108/EC Type-test Self-certification
97/23/EC Self-certification ---------­2006/42/EC Self-certification ---------­2000/14/EC Annex VIII – Full

Quality Assurance

TÜV Industrie Service
GmbH – TÜV SÜD Group
Westendst. 199, D-80686
München GERMANY

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CHAPTER 1

INTRODUCTION

This Operator’s Manual provides the owner/operator information about main­taining and servicing the R105 skid-steer loader model. More impo rtantly, this
manual provides an operating plan for safe and proper use of the machine. Major
points of safe operation are detailed in the Safety chapter of this manual.

We ask that you read and underst and the con tents of this manual completely and
become familiar with your new machine before operating it. See your authorized
Gehl dealer if you have any questions concerning information in the manual,
require extra manuals or for information concerning the availability of manuals
in other languages.

Throughout this manual, information is provided set in italic type and introduced
by the word Note or Important. Read carefully and comply with those messages
– it will improve your operating and maintenance efficiency, help avoid break­downs and damage, and extend your machine’s life.

A manual storage box in the operator’s compartment holds the Operator’s
Manual and AEM Safety Manual (also available in Spanish). Please return the
manuals to this box and keep them with the unit at all times. If this machine is
resold, we recommend that these manuals be given to the new owner.

The attachments and equipment available for use with this machine have a wide
variety of potential applications. Read the manual provided with the attachment
to learn how to safely maintain and operate the equipment. Be sure the machine
is suitably equipped for the type of work to be performed.

Do not use this machine for any applications or purposes other than those
described in this manual or those applicable for approved attachments. If the
machine is to be used with special attachments or equipment other than those
approved by Manitou Americas, consult your Gehl dealer. Any person using non­approved attachments or making unauthorized modifications is resp onsible for
the consequences.

The Gehl dealership network stands ready to provide you with any assistance you
may require, including providing genuine Gehl service parts. A ll service parts
should be obtained from your Gehl dealer. Provide complete information about
the part and include the model and serial numbers of your machine. Record these
numbers in the space provided on the Table of Contents page, as a handy refer­ence.

Manitou Americas strives to continuously improve its products and reserves the
right to make changes and improvements in the design and construction of any
part without incurring the obligation to install such changes on any previously
delivered unit.

If this machine was purchased “used”, or if the owner’s address has changed,
please provide your Gehl dealer or Gehl Company Service Departm ent with the
owner’s name and current address, along with the machine model and serial
number. This will allow the registered owner information to be updated, so that
the owner can be notified directly in case of an important product issue.

50950260/AP1216 1

Loader Identification

1. Upright

2. Lift Cylinder

3. Tires

4. Front Work Lights

5. Handholds

6. Lift Arm

7. Auxiliary Hydraulic Couplers

8. Tilt Cylinders

9. Attachment Bracket

2

3

6

8

9

4

1

7

5

1. Engine Cover

2. Tail Lights

3. Rear Work Lights

4. Rear Door

5. Roll-Over/Falling Object Protective Structure (ROPS/FOPS)

6. Restraint Bar

2

3

4

1

5

6

2 50950260/AP1216

Control/Indicator Symbols

Power Off Power On Engine Start Battery Charge

Worklight w/Tail

Lights

Horn Read Operator’s

H-L

High – Low

Engine Air Filter

Engine Temperature Hydraulic System Hydraulic Oil

Worklight Safety Alert Hazard Flasher Fasten Seatbelt

Manual

N

Neutral

Engine Oil Engine Oil Filter Engine Oil Pressure Fuel Filter

Volume – Full Volume – Half Full Volume – Empty

F

Forward

Hydraulic Oil Filter Grease Lubrication

Temperature

R

Reverse

Electrical Power

Parking Brake

Point

Glow Indicator

Lamp

Fast Slow Ride Control Engine Malfunction

Bucket – Rollback Bucket – Dump

50950260/AP1216 3

Diesel Fuel Chaincase Oil Clockwise Rotation Counterclockwise

Shutdown

Lift Arm – Lower

Lift Arm – Raise Service Hours

Rotation

Bucket – Float

Control/Indicator Symbols, cont.

Battery Disconnect DPF Service Exhaust Gas

Low Fuel Alarm Master Light Switch

Self-Leveling

Windshield Wiper Rear Wiper

Beacon Lock

Unlock Lift Point Windshi eld Washer

Temperature

Position Lights Engine Speed

Fan Heater

DPF Regen

Acknowledgement

Control

Service Interval

DPF Regen

Inhibited

Rear Washer

Temperature

4 50950260/AP1216

CHAPTER 2

DANGER

WARNING

CAUTION

SAFETY

This safety alert symbol means Attention! Become alert! Your safety is
involved! It stresses an attitude of safety consciousness and can be found

throughout this Operator’s Manual and on the decals on the machine.
Before operating this machine, read and study the following safety informati on.

Be sure that everyone who operates or works with this machine, whether family
member or employee, is familiar with these safety precautions. It is essential to
have competent and careful operators, who are not physically or mentally
impaired, and who are thoroughly trained in the safe operation of the machine
and the handling of loads. It is recommended that the operator be capable of
obtaining a valid motor vehicle operator’s license.

The use of skid-steer loaders is subject to certain hazards that cannot be eliminated
by mechanical means, but only by exercising intelligence, care and common sense.
Such hazards include, hillside operation, overloading, instability of the load, poor
maintenance and using the equipment for a purpose for which it is not intended or
designed.

Manitou Americas ALWAYS considers the operator’s safety when designing its
machinery, and guards exposed moving parts for the operator’s protection. How­ever, some areas cannot be guarded or shielded in order to assure proper opera­tion. This Operator’s Manual and decals on the machine warn of additional haz­ards, and they should be read and observed closely.

Some photographs in this manual may show doors, guards or shields open or
removed for illustrative purposes only. Be sure that all doors, guards and shields
are in their proper operating positions before starting the engine to operate the
unit.

Different applications may require optional safety equipment. Users must eval­uate the work-site hazards and equip the machine and the operator as necessary.
The information in this manual does not replace any applicable safety rules and
laws. Before operating the machine, learn the rules and laws for the local area. Be
sure the machine is equipped as required in accordance with these rules/laws.

“DANGER” indicates an imminently haz­ardous situation which, if not avoided, will

result in death or serious injury.

“WARNING” indicates a potentially hazardous
situation which, if not avoided, could result in

death or serious injury.

“CAUTION” indicates a potentially hazardous
situation which, if not avoided may result in

minor or moderate injury. May also alert against unsafe practices.

50950260/AP1216 5

Mandatory Safety Shutdown Procedure

Before cleaning, adjusting, lubricating, servicing the unit, or leaving it
unattended:

1. Move the drive control handle(s) to the neutral position.

2. Lower the lift arm and attachment completely. If the lift arm must be left in

the raised position, BE SURE to properly engage the lift arm support device
(page 21).

3. Move the throttle to the low idle position, shut off the engine and remove the

key.

4. Before exiting, move the lift/tilt control(s) to verify that the controls do not

cause movement of the lift arm and hitch.

Safety Reminders

Before Starting

 Do not modify the ROPS/FOPS unless instructed to do so in installation

instructions. Modifications such as welding, drilling or cutting can w eaken
the structure and reduce the protection it provides. A damaged ROPS/FOPS
cannot be repaired – it must be replaced.

 To ensure safe operation, replace damaged or worn-out parts with genuine

Gehl service parts.

 Gehl loaders are designed and intended to be used only with Gehl attach-

ments and approved attachments. To avoid possible personal injury, equip­ment damage and performance problems, use only attachments that are
approved for use on and within the operating capacity of the machine. Con­tact your dealer or Gehl Service Department for information on attachment
approval and compatibility with specific machine models. Manitou Americas
cannot be responsible if the machine is used with a non-approved attachment.

 Remove all trash and debris from the machine each day, especially in the

engine compartment, to minimize the risk of fire.

 Always face the loader and use the handholds and steps when getting on and

off the loader. Do not jump off the loader.

 Never use starting fluid (ether).
 Walk around the machine and warn all nearby personnel before starting the

machine.

 Always perform a daily inspection of the machine before using it. Look for

damage, loose or missing parts, leaks, etc.

During Operation

 Machine stability is affected by: the load being carried, the height of the load,

machine speed, abrupt control movements and driving over uneven terrain.

DISREGARDING ANY OF THESE FACTORS CAN CAUSE THE
LOADER TO TIP, THROWING THE OPERATOR OUT OF THE

6 50950260/AP1216

SEAT OR LOADER, RESULTING IN DEATH OR SERIOUS INJURY.

Therefore: ALWAYS operate with the seatbelt fastened and the restraint bar
lowered. Do not exceed the machine’s Rated Operating Capacity. Carry the
load low. Move the controls smoothly and gradually, and operate at speeds
appropriate for the conditions.

 When operating on inclines or ramps, always travel with the heavier end of

the loader toward the top of the incline for additional stability.

 Do not raise or drop a loaded bucket or fork suddenly. Abrupt movements

under load can cause serious instability.

 Never activate the float function with the bucket or attachment loaded or

raised, because this will cause the lift arm to lower rapidly.

 Do not drive too close to an excavation or ditch; be sure that the surrounding

ground has adequate strength to support the weight of the loader and the load.

 Never carry riders. Do not allow others to ride on the machine or attachments,

because they could fall or cause an accident.

 Always look to the rear before backing up the skid-steer loader.
 Operate the controls only from the operator’s seat.
 Always keep hands and feet inside the operator’s compartment while oper-

ating the machine.

 New operators must operate the loader in an open area a way from bystanders.

Practice with the controls until the loader can be operated safely and
efficiently.

 Wear safety goggles and head protection while operating the machine. Oper-

ator must wear protective clothing when appropriate.

 Exhaust fumes can kill. Do not operate this machine in an enclosed area

unless there is adequate ventilation.

 When parking the machine and before leaving the seat, check the restraint bar

for proper operation. The restraint bar, when raised, deactivates the lift/tilt
control and auxiliary hydraulics, and applies the parking brake.

 Operator visibility is limited in certain areas; ROPS/FOPS posts, attachments,

the lift arm, items in the cab, etc., can obstruct the operator's view and could
mask hazards or people in the area around the machine. It is very important
the operator is aware of these masked visibility areas before operating the
machine, especially on busy worksites.

To reduce the hazards posed by masked visibility areas:

 Use caution when raising or lowering attachments; masked visibility areas

can change dramatically when attachments and/or the lift arm is moved.

 Look around the machine before operating. Objects near the machine and

close to the ground can be difficult to see from the operator’ s position.

 Always look in the direction of travel, including reverse. A back-up alarm

is not a substitute for looking behind you when operating the machine in
reverse.

 Keep bystanders out of, and away from, the work area.

50950260/AP1216 7

 Keep the lift arm as low as possible while traveling.
 Additional equipment may be installed on the machine to serve as visual

aids (e.g., mirrors, CCTV systems) that provide visibility to areas masked
by the machine structure. Keep all machine components that affect visi­bility in a clean, properly adjusted state and in good working order .

Maintenance

 Never attempt to by-pass the keyswitch to start the engine. Use only the jump

starting procedure detailed in the Operation chapter of this manual.

 Never use your hands to search for hydraulic fluid leaks. Instead, use a piece

of paper or cardboard. Escaping fluid under pressure can be invisible and can
penetrate the skin and cause serious injury. If any fluid is injected into your
skin, see a doctor at once. Injected fluid must be surgically removed by a
doctor or gangrene may result.

 Always wear safety glasses with side shields when striking metal against

metal. In addition, it is recommended that a softer (chip-resistant) material be
used to cushion the blow. Failure to heed could lead to serious injury to the
eyes or other parts of the body.

 Do not smoke or have any spark-producing equipment in the area while filling

the fuel tank or while working on the fuel or hydraulic systems.

Potential Hazards

A skid-steer loader operator must ALWAYS be conscious of the working environ­ment. Operator actions, the environmental conditions and the job being preformed
require the full attention of the operator so that safety precautions can be taken.

ALWAYS maintain a safe distance from electric power lines and avoid contact
with any electrically charged conductor or gas line. Accidental contact or rupture
can result in electrocution or an explosion. Contact the North American One-Call
Referral System at 8-1-1 in the U.S., or 1-888-258-0808 in the U.S and Canada,
for the local “Digger's Hotline” number or the proper local authorities for utility
line locations BEFORE starting to dig!

Exposure to crystalline silica (found in sand, soil and rocks) has been associated
with silicosis, a debilitating and often fatal lung disease. A Hazard Review (Pub.
No. 2002-129) by the U.S. National Institute for Occupational Safety and Health
(NIOSH) indicates a significant risk of chronic silicosis for workers exposed to
inhaled crystalline silica over a working lifetime. NIOSH recommends an expo­sure limit of 0.05 mg/m3 as a time-weighted average for up to a 10-hr. workday
during a 40-hr. workweek. NIOSH also recommends substituting less hazardous
materials when feasible, using respiratory protection and regular medi cal exami­nations for exposed workers.

Static electricity can produce dangerous sparks at the fuel-filling nozzle. Do not
wear polyester, or polyester-blend clothing while fueling. Before fueling, touch
the metal surface of the machine away from the fuel fill to dissipate any built-up
static electricity. Do not re-enter the machine but stay near the fuel filling point

8 50950260/AP1216

during refueling to minimize the build-up of static electricity. Do not use cell
phones while fueling. Make sure the static line is connected from the machine to
the fuel truck before fueling begins.

Ultra-Low Sulfur Diesel (ULSD) poses a greater static ignition hazard than earlier
diesel formulations. Avoid death or serious injury from fire or explosi on; consult
with your fuel or fuel system supplier to ensure the entire fuel delivery system is
in compliance with fueling standards for proper grounding and bonding practices.

Safety Decals

The skid-steer loader has decals that provide safety information and precautions
around the loader. These decals must be kept legible. If missing or illegible, they
must be replaced promptly. Replacements can be obtained from your Gehl dealer.
If there is a decal on a part that is to be replaced, be sure that the decal is applied
to the replacement part.

New Decal Application

Surfaces must be free of dirt, dust, grease and foreign material before applying
the decal. Remove the smaller portion of the decal backing paper and apply the
exposed adhesive to the clean surface, maintaining proper position and align­ment. Peel the rest of the backing paper and apply hand pressure to smooth out
the decal surface. Refer to the following pages for proper decal location. ANSI­style text decals begin on page 10; ISO-style no-text decals begin on page 13.

50950260/AP1216 9

Safety Decals inside the ROPS/FOPS

242582– Located behind the operator’s seat

137683 – Located on
ROPS left panel

137647 – Located on operator’s lower left side

137639 – Located on
ROPS left panel

10 50950260/AP1216

Safety Decals on the outside of the Skid Loader

137655 – Front of loader

50354117 and 50354121 – Front of loader

184214 – Under ROPS

137637 – Lift arm support device, loader left side

50950260/AP1216 11

Safety Decals in the Engine Compartment

50352528

HOT SURFACE

Do not touch hot engine or

hydraulic system parts.

ROTATING FAN

Keep hands out

or stop engine.

50352529

137657 – On right riser

50352528 – On fuel tank

50352529 – On fan
shroud inside engine
compartment

12 50950260/AP1216

ISO-Style (used Internationally)

A – Crush hazard: Keep out from under lift arm unless lift arm is supported.
B – Crush hazard: Keep hands, feet and body inside cab when operating.
C – Forward tip hazard: Fasten seat belt. Carry load low. Do not exceed Rated

Operating Load.

D – Side tip hazard: Avoid steep slopes and high speed turns. Travel up and down

slopes with heavy end uphill.

Safety alert: Read Operator’s
Manual and all safety signs
before using machine. The
owner is responsible to ensure
all users are instructed on safe
use and maintenance.

242568 – Located behind the
operator’s seat

137847 – Part of left
instrument panel

Safety alert: Always follow
“Mandatory Safety Shutdown
Procedure” in Operator’s Manual.

1 – Lower equipment to ground.
2 – Reduce throttle, stop engine.
3 – Apply parking brake; remove

key.

4 – Check safety interlocks.

137849 – Part of
left instrument
panel

Safety alert:
A – Check machine before

operating; Service per Operator’s
Manual. Contact dealer (or
manufacturer) for information and
service parts.
B – Maintain 3-point contact during
entry and exit.
C – Inspect work area. Avoid all
hazards. Look in direction of travel.
Keep children and bystanders away.
D – Start and operate machine only
from seat.
E – Keep away from power lines;
avoid contact.
F – Wear any needed Personal
Protective Equipment. Do not wear
loose clothing while operating or
servicing machine.

AB

C

D

E

F

137843 – Located on operator’s lower left side

ABCD

Safety Decals inside the ROPS/FOPS

50950260/AP1216 13

ISO-Style (used Internationally) Safety Decals

137844 – Located on front of loader

137852 – Located on hitch (manual hitch loaders only)

A – Crush hazard: Keep out from under work tool unless lift arm is supported.
B – Fall hazard: No riders. Never use work tool as work platform.

Crush hazard: Before operating with attachment, check engagement of hitch
locking pin to the attachment:

A – Incorrect attachment engagement C – Lock hitch lever
B – Correct attachment engagement D – Unlock hitch lever

AB

A

B

C

D

137853 – Located on lift
arm support device

Crush hazard: Hose
removal or component
failure can cause lift arm to
drop. Always use lift arm
support device when
leaving arm raised for
service.

on the outside of the Skid-Steer Loader

14 50950260/AP1216

ISO-Style (used Internationally)

137845 – Located on right riser

A – Safety alert: Keep safety devices in place and in working order. Keep guards, screens

and windows in place.
B – Fire hazard: Do not smoke while fueling or servicing machine. Clean debris from
engine compartment daily to avoid fire. Keep fire extinguisher nearby.

C – Run-over hazard: Jump-start per Operator’s Manual procedure.
D – Oil injection hazard: Do not use hands to find hydraulic leaks. Escaping oil under

pressure can be invisible and penetrate skin. Use a piece of cardboard to find leaks.
E – Burn hazard: Allow radiator to cool before removing cap. Loosen cap slowly to avoid
burns.
F – Suffocation hazard: Operate only in a well-ventilated area.

ABCD

EF

50352527

STOP

50352527 – On the fan shroud inside
engine compartment

A – Cutting Hazard, Fan: The fan rotates

at extreme speed.

B – Keep hands away from the fan.
C – Stop the engine before working

around the fan.

A

B

C

50352526

50352526 – On fuel tank

A – Hot surface hazard: The engine and its

components generate temperatures
that can burn skin.

B – Hot surface: Do not touch hot engine or

hydraulic system parts.

B

A

Safety Decals in the Engine Compartment

50950260/AP1216 15

Product and Component Plate Locations

Product and Component Plates

1. Operator protective system plate: with, e.g., model, certification and operator
protective system serial number

2. Seat plate according to ISO 7096

3. Product plate: with Product Identification Number and, e.g., model/type designation

4. Engine plate: with, e.g., type designation, product and serial numbers

5. Component plate hydrostatic pump: with, e.g., product and serial numbers

6. Component plate drive motor: with, e.g., product and serial numbers

1

4

6

5

7

2

3

16 50950260/AP1216

CHAPTER 3

CAUTION

WARNING

WARNING

CONTROLS AND SAFETY EQUIPMENT

Become familiar with and know how to use all

safety devices and controls on the skid-steer
loader before operating it. Know how to stop loader operation befor e
starting it. This Gehl loader is designed and intended to be used
only with a Gehl attachment or a Manitou Americas-approved
referral attachments or accessories. Manitou Americas cannot be
responsible for operator safety if the loader is used with a non­approved attachment.

Guards and Shields

Whenever possible and without affecting loader operation, guards and shields are
provided to protect against potentially hazardous areas. In many places, safety
decals are also provided to warn of potential hazards and/or to display special
operating procedures.

Read and thoroughly understand all safety

decals on the loader before operating it. Do not
operate the loader unless all factory-inst alled guards and shie lds are
properly secured in place.

Operator Restraint Bar

Lower the operator restraint bar after entering the operator’s compartment and sit­ting in the seat. The restraint bar is securely anchored to the ROPS/FOPS. The
operator must be seated with the restraint bar in its lowered position to start or
operate the skid-steer loader. Refer to Safety Interlock System on page 20 for more
information.

The right and left portions of the restraint bar system can be adjusted independent
of one another by pushing the locking lever on the lower inside of either pad. The
restraint pads can then be adjusted to the desired position. The restraint pads lock in
place when the locking lever is released.

Never defeat the operator restraint bar or seat

switch electrically or mechanically. Always
wear the seatbelt.

50950260/AP1216 17

Operator’s Seat

3

Figure 1 Operator’s Seat

1. Restraint Bar

2. Seatbelt

3. Seat Adjustment Level

1

2

3

WARNING

WARNING

Suspension seat (optional): A weight
adjustment knob is provided for indi­vidual operator adjustment.

Upper-Torso Restraint

ALWAYS wear the upper-torso restraint when
operating in High speed.

The seat belt should always be fastened during operation.

Important: Inspect the seat belt(s) for damage before use, and replace if dam­aged. Keep seatbelt(s) clean. Use only soap and water to wash seat belt(s).
Cleaning solvents can cause damage to seatbelt(s).

Safety Interlock System

NEVER defeat the safety interlock system by
mechanically or electrically bypassing any

switches, relays or solenoid valves.

An interlock system is used on the loader for operator safety. Together with
solenoid valves, switches and relays, the interlock system:

 Prevents the engine from starting unless the operator is sitting on the seat and

the operator restraint bar is down.

 Disables the lift arm, attachment tilt and wheel drives when the operator

 Disables auxiliary hydraulic system when the restraint bar is raised or the

Note: The auxiliary hydraulic circuit can be detented in the “ON” position for
continuous operation with the restraint bar raised and operator out of the seat.
(See Auxiliary Hydraulic Controls, page 42.)

18 50950260/AP1216

leaves the seat, turns the keyswitch to OFF or raises the restraint bar.

keyswitch is OFF.

Testing the Safety Interlock System

WARNING

Before leaving a parked machine, check the safety interlock system for proper
operation:

Restraint Bar

With the engine running, raise the restraint bar. Move each of the controls.
There should be not more than a slight movement of the lift arm, attachment
and machine. If there is any significant movement, troubleshoot and correct the
problem immediately. Contact your dealer if necessary.

Seat Switch

With the engine off and the restraint bar lowered, unfasten the seatbelt. Lift
your weight up off the seat. Try to start the engine. If the engine starts, turn off
the engine, and troubleshoot and correct the problem. Contact your dealer if
necessary.

ROPS/FOPS

The ROPS/FOPS (Roll-Over/Falling Object Protective Structure) is designed to
provide protection for the operator from falling objects and in a tip over accident,
if the operator is secured inside the operator’s compartment by the seatbelt and
restraint bar.

Never operate the loader with the ROPS/FOPS

removed or locked back.

50950260/AP1216 19

Parking Brake

Figure 2 Parking Brake Switch -

DPF Models above, Non-DPF

Models below

Figure 3 Rear Window

Emergency Exit

1. Pull Tag

1

This skid-steer loader is equipped with a
spring-applied, hydraulic-released park­ing brake. The parking brake engages
when the operator lifts the restraint bar,
exits the seat or shuts off the engine. The
brake can also be applied manually by
using the switch located on the right
instrument panel. A red indicator in the
switch lights when the parking brake is
applied.

Horn

On hand/foot loaders, pressing the right button on the left contro l handle sounds
the horn. On T-bar loaders, pressing the bottom button on the left control handle
sounds the horn.

Rear Window Emergency Exit

The ROPS rear window has three func­tions: noise reduction, flying objects bar­rier and emergency exit.

To use the emergency exit, pull on the
yellow warning tag at the top of the
window and remove the seal. Push or kick
out the window and then exit.

See your local automotive glass specialist
to reinstall the window.

20 50950260/AP1216

Lift Arm Support Device

WARNING

Figure 4 Lift Arm Support

Device Engaged

WARNING

The lift arm support device is used as a cylinder lock to prevent the raised lift arm
from lowering unexpectedly. Be sure to install the support device when the lift
arm is raised for service. When the support device is not being used, return it to
its storage position. The support device is a safety device, which must be kept in
proper operating condition at all times. The following steps ensure correct usage:

The safest method of engaging the lift arm sup-

port device requires two people - one person
inside the loader and another person outside the loader to engage
the support device.

Note: With the key switch OFF and the solenoid valve working properly, the lift
arm will stay raised when the lift control is moved to lower the lift arm. If the
valve does not hold the lift am and it begins to lower do not leave the op erator ’s
compartment. Instead, lower the lift arm and exit the machine. Then, contact
your Gehl dealer immediately to determine why the lift arm lowers while the key
switch is OFF.

Engagement

T o engage the lift arm support device:

1. Lower the lift arm fully.

2. Stop the engine.

3. Have an assistant remove the lift arm

support device from its storage loca­tion (Figure 4) on the left side of the
machine. Remove the lynch pin hold­ing the support device up against the
lift arm. Allow the support device to
come down into contact with the lift
cylinder (Figure 4).

4. Restart the engine.

5. Use the lift control to raise the lift arm

until the support device drops over the end of the lift cylinder and around t he
cylinder rod. Slowly lower the lift arm until the free-end of the support device
contacts the top end of the lift cylinder.

6. Look to be sure the support device is secure against the cylinder end. Then,

stop the loader engine, remove the key and exit the operator’s compartment.

Disengagement

– one person inside the loader and another person outside the
loader to disengage the support device.

Important: W ith the key switch OFF and the solenoid valve working pr operly, the
lift arm will stay raised when the lift control is moved to lower the lift arm. If the

50950260/AP1216 21

The safest method of installing and removing

the lift arm support device requires two people

valve does not hold the lift am and it begins to lower do not leave the op erator ’s

Figure 5 Lock Pin

in storage Position

compartment. Instead, lower the lift arm and exit the machine. Then, contact
your Gehl dealer immediately to determine why the lift arm lowers while the key
switch is OFF.

To return the lift arm support device to its
storage position:

1. Start the engine.

2. Raise the lift arm fully.

3. Stop the engine.

4. Verify that the lift arm is being held in

the raised position by the safety inter­lock system.

5. To store the support device, have an

assistant raise it up until it contacts the
lift arm. Reinstall the lynch pin
through the welded steel post on the
lift arm (Figure 5).

Accessory Plug

The 12-V accessory plug is located at the bottom of the right instrument panel.

Dome Light

The dome light is located on the left side of the ROPS/FOPS headliner. Push on
the dome light to switch it on.

Work Lights

Loaders have two sets of work lights. The front work lights are located at the top
of the ROPS/FOPS. The rear work lights are located at the top of the rear grille.

Heater (optional)

Loaders with the optional heater have two control knobs on top of th e heater uni t
for controlling fan speed and heater temperature.

1. Fan Speed Control Knob: Controls the fan speed and turns the heater sys-

tem on or off.

2. Temperature Control: The rotary knob regulates the temperature of the

heated air. Rotate clockwise to increase the temperature; counterclockwise to
decrease the temperature.

22 50950260/AP1216

Lockable Fuel Cap

CAUTION

Though not necessary to leave locked, the use of a locking fuel cap protects the
loader from fuel theft or fuel system vandalism. The key to this lockable fuel cap
should be secured to the loader’s key ring. A torque override features aids in the
proper installation of the fuel cap. It produces an audible click as the o-ring that
seals the cap is properly compressed. To operate the lockable fuel cap:

1. Shut off the engine and remove the key. Insert the fuel cap key into the fuel

cap lock.

2. Turn the key 45° clockwise to unlock the fuel cap and turn the cap off the fuel

fill neck. When finished fueling the loader, replace the cap and tighten it.
Holding the cap, insert the key and turn it 45° counterclockwise to lock the
cap in place. Remove the key and check the lock by trying to open the cap.

In the event the key to t he lockable fuel cap is

lost, contact your dealer or a local locksmith to
prevent damage to the cap.

50950260/AP1216 23

Engine Speed Control

Figure 6 Engine Speed Control -

DPF Models above, Non-DPF

Models below

Figure 7 Foot Throttle - DPF

Models above, Non-DPF Models

below

On DPF Models, an engine speed control
(Figure 6) is provided for setting the
engine speed. Move the control clockwise
to increase the engine speed, and counter­clockwise to decrease the engine speed.
Engine speed may be limited while diag­nostic trouble codes (DTC’s) are active or
during a cold start. See the engine diag­nostic chart for the DTC’s on page 73 or
the cold starting procedure on page 42.

On Non-DPF Models, a right-hand con­trolled throttle lever is provided on all
models for adjusting the engine speed.
Move the control forward to increase the
engine speed and rearward to decrease the
engine speed.

With T-bar controls, a foot pedal
(Figure 7) is provided as a secondary
throttle, which can be used to override the
engine speed control. If the foot throttle is
released, the engine will return to the
speed set by the engine speed control.

24 50950260/AP1216

Float Control

WARNING

For hand/foot loaders, use your toes to push the left foot pedal all the wa y down to
detent the float control. For T-Bar loaders push the right control handle fully for­ward to detent the float control. This mode allows the lowered lift arm to follow
the ground contour while traveling over changing ground conditions. For
hand/foot loaders, use your heel to push the left foot pedal up to horizontal to
deactivate. For T-bar loaders, pull the right control handle rearward to deactivate.
The float mode is automatically deactivated when the machine is shut off.

Never use the float mode with the attachment

raised, because this will cause the lift arm to
lower very rapidly. The float mode can be used where the engine ha s
stopped, is unable to be started, and lowering the lift arm is neces­sary to allow the operator to exit the loa d er.

50950260/AP1216 25

Instrument Panel (DPF Models)

1

2

3

4

5
6

7

8

Figure 8 Instrument Panel

9

10

11

12

13

14

The instrument panel contains the following
switches and indicators. Symbols on the panel
represent various functions and conditions, and
are visible only when indicator lamps are on.

1. Keyswitch – In a clockwise rotation, these

positions are:
OFF Position – With the key vertical,

power from the battery is disconnected from
the controls and instrument panel electrical
circuits. This is the only position from
which the key can be inserted or removed.

ON (or RUN) Position – With the key
turned one position clockwise from vertical,
power from the battery is supplied to all
control and instrument panel circuits.

START Position – With the key turned
fully clockwise, the electric starter engages,
to start the engine. Release the key to RUN
position after the engine starts.

Note: The engine cannot be sta rted unless the
operator is sitting in the seat and the restraint
bar is lowered.

2. Information Center Electronic Display –

See page 29.

3. Fuel Level Gauge – Displays the amount of

fuel in the tank.

4. Fasten Seatbelt – A momentary visual (and

audible) indicator to remind the operator to
fasten the seatbelt.

5. Engine Oil Pressure – Lights if the engine

oil pressure drops too low, warning the oper ­ator to immediately stop the engine and
determine the cause for the pressure drop.
During normal operation, this indicator
should be OFF.

6. Battery – Lights if the charging voltage is

too high or too low. During normal opera­tion, this indicator should be OFF.

7. Preheat Indicator Lamp – Lights when the

(automatic) preheat is active. During normal
operation this indicator should be OFF.

26 50950260/AP1216

8. Engine Malfunction Lamp – Indicates the engine ECU has detected a mal-

function of the engine.

9. Engine Coolant Temperature – Lights if the engine coolant becomes too

hot, warning the operator to stop the engine. Allow the engine to cool , deter­mine the cause for the high temperature and correct the problem before
restarting the engine. During normal operation, this indicator should be OFF.

10.Hydraulic Oil Temperature – Lights if the hydraulic oil becomes too hot,

warning the operator to stop engine. Allow the hydraulic system to cool and
determine the cause of the high temperature. During normal operation, this
indicator should be OFF.

11.Parking Brake Switch – Used to manually apply the parking brake. Ligh ts

when the parking brake is applied.

12.Engine Speed Control – Controls the engine speed. Move the control clock-

wise to increase and counter-clockwise to decrease the engine speed.

13.Light Switch – Controls all the lights on the loader. Symbols denote the four

positions of the light switch. In a clockwise direction these are:

•OFF

• Tail Lights ON

• Front W o rk Lights with Tail Lights ON

• both Front and Rear Work Lights
For the lights to function, the keyswitch must be in the RUN position.

14. Accessory Outlet – 12-volt DC power outlet.

50950260/AP1216 27

Instrument Panel (Non-DPF Models)

1

2

3

4
5
6

7

8

Figure 9 Instrument Panel

9

10

11

12

13

14

The instrument panel contains the following
switches and indicators. Symbols on the panel
represent various functions and conditions, and
are visible only when indicator lamps are on.

1. Hourmeter – Displays the total operating

hours on the loader.

2. Fuel Level Gauge – Displays the amount of

fuel in the tank.

3. Engine Coolant Temperature Gauge –

Indicates the engine coolant temperature.

Note: Items 4 through 9 are indicator lamps
which display the following:

4. Fasten Seatbelt – A momentary visual (and

audible) indicator to remind the operator to
fasten the seatbelt.

5. Engine Oil Pressure – Lights if the engine

oil pressure drops too low, warning the oper­ator to immediately stop the engine and
determine the cause for the pressure drop.
During normal operation, this indicator
should be OFF.

6. Battery – Lights if the charging voltage is

too high or too low. During normal opera­tion, this indicator should be OFF.

7. Preheat Indicator Lamp – Lights when the

preheat switch is pressed. During normal
operation, this indicator should be OFF.

8. Engine Coolant Temperature – Lights if

the engine coolant becomes too hot, warning
the operator to stop the engine. Allow the
engine to cool, determine the cause for the
high temperature and correct the problem
before restarting the engine. During normal
operation, this indicator should be OFF.

9. Hydraulic Oil Temperature – Lights if the

hydraulic oil becomes too hot, warning the
operator to stop engine. Allow the hydraulic
system to cool and determine the cause of
the high temperature. During normal opera­tion, this indicator should be OFF.

28 50950260/AP1216

10.Keyswitch – In a clockwise rotation, these positions are:
OFF Position – With the key vertical, power from the battery is disconnected

to the controls and instrument panel electrical circuits. This is the only posi­tion the key can be inserted or removed from the keyswitch.

ON (or Run) Position – With the key turned one position clockwise from
vertical, power from the battery is supplied to all control and instrument panel
electrical circuits.

START Position – With the key turned fully clockwise, the electric starter
energizes, start the engine. Release the key to the RUN position after the
engine starts.

Note: The engine cannot be started unless the operator is sitting in the seat and
the restraint bar is lowered.

11.Parking Brake Switch – Used to manually apply the parking brake. The red indicator on the switch lights when the parking brake is applied.

12.Light Switch – Controls all the lights on the loader. Symbols denote the four positions of the light switch. In a clockwise direction these are:

•OFF

• Tail Lights ON

• Front Work Lights with Tail Lights ON

• both Front and Rear Work Lights
For the lights to function, the keyswitch must be in the RUN position.

13.Circuit Breakers – Four circuit breakers on the instrument panel protect the loader’s electrical circuits.

Important: Do not attempt to defeat the circuit protection by jumping across a
circuit breaker or by using a higher amperage circuit breaker.

14. Accessory Outlet – 12-volt DC power outlet.

50950260/AP1216 29

T-Bar Controls

Figure 10 T-Bar Controls

1. Drive Control

2. Lift/Tilt Control

1

2

WARNING

WARNING

The loader may be equipped with T-bar
controls (Figure 10). The left T-bar con­trols the drive and the right T-bar controls
the lift/tilt.

Drive Controls

Forward, reverse, speed and turning
maneuvers are accomplished by move­ment of the left T-bar. To go forward,
push the control forward; for reverse, pull
the control rearward. To turn right, turn
the control clockwise; to turn left, turn the
control counterclockwise. For gradual turns, move the T-bar slightly forward or
rearward. For sharp turns, turn the control clockwise or counterclockwise.

Moving the T-bar farther from neutral increase the speed steadily to the max­imum travel speed. Tractive effort decreases as speed increases. To get maximum
tractive effort, move the T-bar only slightly away from the neutral position. The
engine will stall if the control is moved too far forward when loading the bucket.

Be sure the controls are in neutral before

starting the engine. Operate the controls grad­ually and smoothly. Excessive speed and quick control movements
without regard for conditions and circumstances are hazardous and
could cause an accident.

Lift/Tilt Control

Moving the lift arm and tilting the attachment are accomplished by movement of
the right T-bar. To raise the lift arm, pull the control straight rearward; to lower
the lift arm, push the control straight forward. To tilt the attachment forward

and downward, twist the control clockwise; to tilt the attachment up and
back, twist the control counterclockwise..

Note: The speed of the lift/tilt motion is directly proportional to the amount of
T-Bar movement and engine speed.

To place the lift arm into the detent (“float”) position, push the right T-Bar all the
way forward into the detent. This position allows the lowered lift arm to “flo at”
while traveling over changing ground conditions.

Never push the right control handle fully for-

ward to detent the float control wi th the attach­ment raised, because this will cause the lift arm to lower very
rapidly.

30 50950260/AP1216

Hand/Foot Controls

Figure 11 Hand/Foot Controls

1. Left Drive Control Handle

2. Right Drive Control Handle

3. Tilt Control Foot Pedal

4. Lift Control Foot Pedal

1

2

3

4

WARNING

The loader may be equipped with
hand/foot controls (Figure 11). The con­trol grips control the drive and the foot
pedals control the lift/tilt.

Drive Controls

Forward, reverse, speed and turning
maneuvers are accomplished by movement
of the control grips. To go forward, push
both control grips forward; for reverse,
pull both control grips rearward. For
turning, move one control grip farther for­ward or rearward than the other control
grip. Turn direction is determined by
which control grip is moved farther for­ward. To turn left, move the right control grip farther forward than the left control
grip; to turn right, move the left control grip farther forward than the right control
grip. For sharp turns, move the control grips in opposite directions.

Moving the control grips farther from neutral increases the speed steadily to the
maximum travel speed. Tractive effort decreases as speed increases. For maximum
tractive effort, move the control grips only slig htly away from the neutr al positions.
The engine will stall if the control grips are moved too far forward when loading
the bucket.

Be sure the controls are in neutral before

starting the engine. Operate the controls grad­ually and smoothly. Excessive speed and quick control movements
without regard for conditions and circumstances are hazardous and
could cause an accident.

Lift/Tilt Controls

Moving the lift arm and tilting the attachment are accomplished by movement of
the foot pedals. The left pedal raises and lowers the lift arm; the right pedal tilts
the attachment. T o raise th e lift arm, pus h down on the back of the left pedal with
your left heel; to lower the lift arm, push down on the front of the left pedal with
the toes of your left foot. To tilt the attachment forward and down, push down
on the front of the right pedal with the toes of your right foot; to tilt the attach-
ment up and back, push down on the back of the right pedal with your right
heel.

Note: The speed of the lift/tilt motion is directly proportional to the amount of
pedal movement and engine speed.

To place the lift arm in the detent (“float”) position, use your toes to push the left
pedal all the way down into the detent. This po sition allows the l owered lift arm
to “float” while traveling over changing ground conditions.

50950260/AP1216 31

Never push the left pedal into the float position

WARNING

Figure 12 Auxiliary Couplers

A

B

Figure 13 T-Bar Auxiliary

Control

Figure 14 Hand/Foot

Auxiliary Control

with the attachment loaded or raised, because

this will cause the lift arm to lower rapidly .

Auxiliary Hydraulic Controls

Auxiliary hydraulics are used with attach­ments that have a mechanism requiring
hydraulic power.

Important: Always be sure the auxiliary
hydraulic control is in neutral before
starting the loader or removing the auxil­iary hydraulic couplers.

Note: When ignition power is interrupted,
auxiliary hydraulic function is reset to
OFF.

Couplers are located on the left lift arm.
“A” port is pressure, “B” port is return
when the auxiliary control is in the detent position (refer to page 45).

T-Bar Controlled Loaders

A foot pedal is used to control the direc­tion of oil flow.

Hand/Foot Controlled Loaders

The right handle controls the direction of
oil flow. A locking pin locks it in the up
position for continuous operation.

32 50950260/AP1216

Attachment Mounting

Figure 15 All-Tach™

Attaching Mechanism (Hitch)

WARNING

Figure 16 Battery Disconnect

Switch

The Gehl loader is equipped with a
two-pin All-Tach™ attachment bracket
for mounting a bucket or other attach­ment. Two latch levers secure the attach­ment. Rotate the levers until they are hori­zontal to engage the latch pins. Rotate the
levers until they are vertical to disengage
the latch pins.

To prevent unexpected release of the attach-

ment from the hitch, be sure to secure the latch
pins by rotating the levers all the way to the hitch.

Electrical Battery Disconnect Switch (optional)

An optional electrical battery disconnect
switch is located inside the engine com­partment on the left side and forward of
the fuse panel. Turn the switch to the OFF
position to disconnect the battery from the
electrical system.

50950260/AP1216 33

Information Center Electronic Display (DPF

ok

Figure 17 – Information Center Electronic Display

M

O

P

Q

N

R

Models)

The information center electronic display is located on the right door pillar. It
provides the following functionality:

• Displays operational status such as engine RPM, coolant temperature and service
hours.

• Displays error fault codes and input/output diagnostic data.

• Configures displays settings.

P. Increase Brightness/Return Button – Used for
different functions depending upon screen and
context:

M. Navigation Rocker Button – Used for general
screen navigation and other various functions,
depending upon screen and context.

N. OK Button – Used for various functions,
depending upon screen and context.

34 50950260/AP1216

• Used to increase display brightness.
Corresponds to the symbol on the
display screen.

• Used to return to previous screen.
Corresponds to the symbol on the
display screen.

Q. Decrease Brightness Button – Used to
decrease display brightness. Corresponds to

the symbol on the display screen.

O. Regen/Return Button – Used for different

WARNING

n/min

functions depending upon screen and context:

• Switches to the Regen display mode if the
symbol is displayed on the screen. Also

initiates DPF regeneration if all appropriate
conditions are met.

• Used to return to previous screen.

Corresponds to the symbol on the
display screen.

R. Regen Inhibit Button (DPF models) – Press
for 5 seconds to inhibit DPF reset regeneration.

Displays the symbol.

If the LCD is broken, care must be taken with

any leaking fluid. If LCD fluid gets onto your
skin, wipe with a cloth and wash the area with mild soap and water . If
LCD fluid gets into your eyes, th orou ghly rinse your e yes with clea n
water for several minutes and seek medical assistance. If LCD fluid
is swallowed, rinse your mouth thoroughly with clean water, then
drink a substantial volume of water and induce vomiting. Then seek
medical assistance.

Information Center Electronic Display Symbols

The following table describes symbols used in the information center electronic
display.

Note: Values may not display for all parameters, depending upon installed
options and equipment.

Table 1: Symbols Descriptions

Symbol Description Symbol Description

Engine crankshaft revolutions per
minute.

Accumulated operation time. Time
is displayed in hours, and
accumulates when the engine is
running.

Battery charging circuit voltage.

Coolant temperature.

50950260/AP1216 35

Real-time fuel consumption rate.
Displayed in gallons/hour (SAE)
or liters/hour (METRIC).

Display brightness increase.
Press button (P, Figure 17) when
this symbol is displayed to
increase screen brightness.

Display brightness decrease.
Press button (Q, Figure 17) when
this symbol is displayed to
decrease screen brightness.

Diesel Particulate Filter (DPF)
regeneration (DPF Models). See
“Diesel Particulate Filter (DPF)
Regeneration Procedures (DPF
Models)” on page 55.

Table 1: Symbols Descriptions

%

Symbol Description Symbol Description

Diesel Particulate Filter (DPF)
regeneration inhibit (DPF Models).
See “Diesel Particulate Filter

Percentage of engine power
based on load.

(DPF) Regeneration Procedures
(DPF Models)” on page 55.

Note: Strike-through line
through the symbol is dis­played in red when DPF
regeneration is inhibited.

Diesel Particulate Filter (DPF)

regeneration in-progress
Ambient engine compartment
temperature.

(elevated temperature). See

“Diesel Particulate Filter (DPF)

Regeneration Procedures (DPF

Models)” on page 55.

36 50950260/AP1216

Information Center Electronic Display Screens

1234.5
C

H

A

C

E

F

B

D

1234.5

12.5 28.0

1000

n/min

T

Note: Values may not display for all parameters, depending upon installed
options and equipment.

Table 2: Status, Maintenance and Error Code Screens

Display Mode Description

Status Screens

Dual Gauge Display

A. Accumulated operation time.

Note: Time is displayed in hours, and accu­mulates when the engine is running.

B. Engine coolant tem perature.
C. Amber error condition warning. Causes DM1/DM2

errors screen(s) to display. See page39.

D. Red crit ical error w arning. Causes DM1/DM2 errors

screen(s) to display. See page39.

E. Engine coolant temperature amber warning region.

Indicates elevated coolant temperature.

F. Engine coolant temperature red stop warning

region. Indicates serious coolant overheating
condition.

Note: Running the engine in an overheated
condition can damage the engine.

Quad Gauge Display

Displays four different status parameters
simultaneously. To change the displayed parameters,
press and hold the ok button (N, Figure 17) until orange
bar (T) displays. Press the left/right side of navigation
rocker button (M, Figure 17) to select the parameter and
press the top/bottom of navigation rocker button to
change the selected parameter. Press the ok button
again to dismiss orange bar (T).

50950260/AP1216 37

Table 2: Status, Maintenance and Error Code Screens

212

1234.5

n/min

22 %

REVISIONS

DISPLAY

04 14 2014

MCU

MAIN KEYPAD

ABCDEFG

ROAD LIGHTS KEYPAD

HEATER/WIPER KEYPAD

ABCDE

************

************

Display Mode Description

Single Gauge Display

Displays single real time operating parameters.
Switch between parameters using the navigation
button (M, Figure 17). Used for various functions,
depending upon screen and context.

Regeneration Screens (DPF Models)

These screens are associated with Diesel
Particulate Filter (DPF) regeneration procedures
and maintenance. See “Diesel Particulate Filter
(DPF) Regeneration Procedures (DPF Models)” on
page 55.

Secondary Screens

Secondary screens are accessed by holding down
the ok button (N, Figure 17) for 10 seconds while

All Secondary Screens

the Dual Gauge Display screen is displayed. Press
the left/right side of navigation rocker button (M,
Figure 17) to switch between secondary screens.

Revision Screen

Displays information center electronic display
software information.

38 50950260/AP1216

Table 2: Status, Maintenance and Error Code Screens

UNITS

SAE

LANGUAGE

ENGLISH

DM1

SPN: 0

0 of 0

FMI: 0
OCI: 0

T

DM2

SPN: 0

0 of 0

FMI: 0
OCI: 0

T

Display Mode Description

Press the top/bottom of navigation rocker button
(M, Figure 17) to switch between SAE or metric
units for values displayed in screens.

Language Screen

The press the top/bottom of navigation rocker
button (M, Figure 17) to switch between English or
Spanish language for values displayed in screens.

Displays engine, drive system, control, and safety
system error code message information. Number of
available messages is displayed at the top left of
the screen (T). Use buttons (P and Q, Figure 17) to
scroll through the messages. See “Engine
Diagnostic Chart (DPF Models)” on page 73 for
specific error code details.

Units Screen

DM1 Screen

50950260/AP1216 39

DM2 Screen

Continuation of error code message display along
with DM1 Screen. Number of available messages is
displayed at the top left of the screen (T). Use
buttons (P and Q, Figure 17) to scroll through the
messages. See “Engine Diagnostic Chart (DPF
Models)” on page73 for specific error code details.

Table 2: Status, Maintenance and Error Code Screens

DIAGNOSTICS INPUTS

Float

Hydro Glide

High Gear

Aux Detent

Air Filter Clog

Alternator

KP Ingnition Run

KP Ignition Start

KP Seat Switch

KP Restraint Bar

Hyd Filter Clog
High Hyd Temp

Engine Pressure

DIAGNOSTICS OUTPUTS

High Gear
Self Level

Hydro Glide

Fuel Pump

Glow Plug

Float

Marker Lts
Rear Work Lts
Front Work Lts
KP Beacon Lts

KP Dome Lt

Disable Park Brake

Tilt/Lift

Starter

All Tach Lock

All Tach Unlock

Display Mode Description

Displays input information from electronic control
modules, showing real-time machine
component/control state. Status colors indicate the
following:

• Green – Active

• Black – Inactive

Displays output informati on from electronic control
modules, showing real-time feedback state of
machine components. Status colors indicate the
following:

• Green – Active

• Black – Inactive.

• Yellow – Standby or Not Applicable

• Red – Short Circuit

Input Status

Output Status

40 50950260/AP1216

CHAPTER 4

WARNING

OPERATION

Before starting the engine and operating the

loader, review and comply with all safety rec­ommendations in the Safety chapter of this manual. Know how to
stop the loader before starting it. Also, be sure to fasten and prop­erly adjust the seatbelt(s) and lower the operator restraint bar.

Before Starting the Engine

Before starting the engine and running the loader, refer to the Controls and Safety
Equipment chapter and become familiar with the various operating controls, indi-

cators and safety devices on the loader.

Fuel

Use only ultra-low sulfur diesel fuel to maintain proper engine performance. Use
of diesel fuel with more than 15 ppm of sulfur can potentially damage the engine.
BioDiesel mixtures of up to a 7% (B7) are acceptable. Ultra-Low Sulfur Diesel
(ULSD) fuel lubricity must have a maximum scar diameter of 0.45 mm, as mea­sured by ASTM D6079 or ISO 12156-1, or a minimum of 3100 grams, as mea­sured by ASTM D6078. Contact your fuel suppli e r fo r details.

Static electricity can produce dangerous sparks at the fuel-filling nozzle. Do not
wear polyester, or polyester-blend clothing while fueling. Before fueling, touch
the metal surface of the machine away from the fuel fill to dissipate any built-up
static electricity. Do not re-enter the machine but stay near the fuel filling point
during refueling to minimize the build-up of static electricity. Do not use cell
phones while fueling. Make sure the static line is connected from the machine to
the fuel truck before fueling begins.

Ultra-Low Sulfur Diesel (ULSD) poses a greater static ignition hazard than ear­lier diesel formulations. Avoid death or serious injury from fire or explosion;
consult with your fuel or fuel system supplier to ensure the entire fuel delivery
system is in compliance with fueling standards for proper grounding and bonding
practices.

Starting the Engine

The following procedure is recommended for starting the engine:

1. Carefully step up onto the back of the bucket or attachment and grasp the

handholds to enter the operator’s compartment.

2. Close the door, fasten the seatbelt(s) and lower the restraint bar.

3. Verify the following:

 the lift/tilt, drive and auxiliary hydraulic controls are in their neutral posi-

tions,

50950260/AP1216 41

 the parking brake switch is ON.

WARNING

Note: When the key is turned to the RUN position, an indicator lamp will light on
the instrument panel and a chirp will sound momentarily to remind users to
fasten the seatbelt

4. Turn the key to the START position.

Note: If temperature is below 32° F (0° C), see Cold-Starting Procedure, on page

46.
Important: Do not engage the starter for longer than 15 seconds at a time.

Longer use can overheat and damage the starter . If the engine fails to start within
15 seconds, return the key to the OFF position or check for engine error codes.
Allow the starter to cool for 20 seconds and repeat step 4.

After the engine starts, allow a five minute low idle warm-up period befo re oper­ating the controls.

Important: Avoid extended engine idling after the engine reaches normal oper­ating temperature to prevent frequent DPF regenerations. If the indicator
warning lamps do not go off, stop the engine and investigate the cause.

Cold-Starting

If the temperature is below 32° F (0° C), the following is reco mmended to m ake
starting the engine easier:

 Replace the engine oil with API-CJ-4/SAE 5W-30 oil as recommended by

the viscosity chart;

 Make sure the battery is fully charged;
 Install a block heater on the engine.

Let the engine run for a minimum of five minutes to warm the engine and
hydraulic fluid before operating the loader. A block heater is recommended for
starting in temperatures of 14° F (-10° C) or lower. See your dealer for heater
options.

Cold Starting Procedure

Do not use starting fluid (ether) with preheat
systems. An explosion can result which can

cause engine damage, injury or death.

1. Turn the key to the RUN position. If the preheat li ght on the right i nstrument panel comes on, wait for this symbol to go out.

2. Immediately turn the key to the START position.

3. If engine does not start, return key to OFF position and repeat steps 1 and 2.

Important: During cold start conditions, the recommended limit of continuous
starter engagement is 15 seconds and the starter must never be energized for

42 50950260/AP1216

more than 30 seconds. If the starter is energized for 20-30 seconds, the loader
should be turned off for one minute or longer. To protect the starter (DPF
Models), the E-ECU system turns off the starter circuit if it is energized for 30
seconds or longer. The starter will remain de-energized for 30 seconds more
before the loader can be restarted.

Upon a successful start, let the engine run for a minimum of five minutes to
warm the engine and hydraulic fluid before operating the loader.

Cold Start Aids

 At an ambient temperature of 32° F (0° C) or below, no starting aids are

required. However, as with any diesel vehicle, using the recommended
engine oil, maintaining a healthy battery and installing an engine block
heater are sound practices to improve cold-starting performance and pro­longing starter life.

 At an ambient temperature of 14° F (-10° C) or below, a healthy battery is

essential as glow cycles and cranking cycles can induce a substantial load
on the battery during start. An engine block heater is recommended at this
temperature to reduce starter load and improve the engine war m-up period
prior to loader operation. Attempting to start the loader without a block
heater will result in multiple glow/crank cycles or possible extended
cranking time approaching 20 seconds.

 At an ambient temperature of 5° F (-15° C) or below, a healthy battery is

imperative. A recommended battery charger/maintainer applied before or
during a start cycle will help maintain 12 V to the starter circuit during a
potential long crank cycle of 20 seconds or more. A required block heater
will reduce starter load, reduce crank time and improve the overall engine
warm-up time during extreme cold starts.

Stopping the Loader

The following procedure is the recommended sequence for stopping the loader:

1. Check that the drive control handle(s) is (are) in neutral position.

2. Lower the lift arm and rest the attachment on the ground.

3. Turn throttle knob back to the low idle position (and release the throttle pedal

for T-bar control machines). Allow the engine to idle for five minutes if the
engine was operated under full load.

4. Turn the keyswitch to the OFF position and remove the key.

5. Move the lift/tilt control to verify that the safety interlock system is prevent-

ing movement.

6. Raise the restraint bar, unfasten the seatbelt(s) and grasp the handholds while

climbing out of the operator’s compartment.

Note: The skid-steer loader is equipped with a spring-applied automatic parking
brake. The parking brake is applied when the operator lifts the restraint bar,

50950260/AP1216 43

leaves the operator’s seat or shuts off the engine, or actuates the parking brake

WARNING

switch.

Parking the Loader

Park the loader away from traffic on level ground. If this is not possible, park the
loader across the incline and block the tires to prevent movement.

Jump Starting the Engine

If the battery becomes discharged or does not have enough power to start the
engine, use jumper cables and the following procedure to jump-start the engine.

The ONLY safe method for jump-starting a

discharged battery is for TWO PEOPLE to
perform the following procedure. The second person removes the
jumper cables so that the operator does not have to leave the
operator’s compartment with the engine running. NEVER make
jumper cable connections directly to the starter solenoid of either
engine. DO NOT start the engine from any position other than on
the operator’s seat and then ONLY after being sure ALL controls
are in “neutral.”

Closely follow the procedure, in order, to avoid personal injury. In
addition, to protect your eyes wear safety glasses and avoid
leaning over the batteries while jump-starting.

DO NOT jump-start the battery if it is frozen, because it may rupture or explode.

Note: BE SURE the jumper battery is a 12-volt D.C. battery.

1. Turn the keyswitches of both vehicles to OFF, be sure the vehicles are in

“neutral” and NOT touching each other.

2. Connect the positive (+) jumper cable to the positive (+) battery terminal on

the disabled loader first. DO NOT allow the positive clamps to touch any
metal other than the positive (+) battery terminals.

3. Connect the other end of the positive jumper cable to the jumper vehicle’s

battery positive (+) terminal.

4. Connect the negative (-) jumper cable to the jumper vehicle’s battery negative

(-) terminal.

5. Make the final negative (-) jumper cable connection to the disabled loader’s

engine block or loader frame (ground), such as the rear grille latch post –
NOT to the disabled battery’s negative post. If connected to the engine, keep
the jumper clamp away from the battery, fuel lines and moving parts.

6. Start the loader. If it does not start at once, start the jumper vehicle engine to

avoid excessive drain on the booster battery.

7. After the disabled loader is started and running smoothly, have the second

person remove the jumper cables (negative (-) jumper cable first) from the

44 50950260/AP1216

jumper vehicle’s battery and then from the disabled loader while being sure

WARNING

Figure 1 Hitch – disengaged

1. Latch Levers

2. Latch Pins

1

1

2

2

NOT to short the two cables together.
Allow sufficient time for the skid-steer loader alternator to build-up a charge in
the battery before attempting to operate the loader or shut the engine off.

Changing Attachments

To prevent unexpected release of the attach-

ment from the hitch, be sure to secure the latch
pins by rotating the levers all the way to the hitch. Locking pins
must be fully engaged through the holes in the attachment frame
before using the attachment. The attachment could fall off if it is not
locked on the hitch and cause serious injury or death.

The skid-steer loader features a All-Tach™ attaching mechanism for mounting a
bucket or other attachment. Two latch levers engage the latch pins to secure the
attachment.

Connecting an Attachment

1. Rotate the latch levers to a vertical

position to fully retract the latch pins.

2. Start the loader engine and be sure the

lift arm is lowered and in contact with
the loader frame.

3. Align the loader squarely with the

back of the attachment.

4. Tilt the hitch forward until the top

edge of the hitch is below the flange
on the back side of the attachment and
centered between the vertical plates.

5. Slowly drive the loader forward and,

at the same time, tilt the hitch back to
engage the flange on the back side of
the attachment.

6. Stop forward travel when the flange is engaged, but continue to tilt the hitch

back to lift the attachment off the ground.

7. Exercise the MANDATORY SAFETY SHUTDOWN PROCEDURE

(page 6).

8. With the loader engine OFF, leave the operator’s compartment and rotate the

latch levers all the way to the hitch to fully engage the latch pins.

Important: To check that the attachment is properly installed tilt the attachment
forward slightly, apply downward pressure to the attachment prior to operating.

50950260/AP1216 45

Connecting Auxiliary Hydraulic Couplings

WARNING

Note: With the engine OFF, key in the ON position and the restraint bar down,
the auxiliary hydraulic control can be moved to relieve any pressure in the
hydraulic system.

The hydraulic couplers are located on the left lift arm. “A” port is pressure, “B”
port is return when the auxiliary control is in the detent position.

Removing Attachments

1. Tilt the hitch back until the attachment is off the ground.

2. Exercise the MANDATORY SAFETY SHUTDOWN PROCEDURE

(page 6).

3. Relieve any hydraulic pressure in the auxiliary and attachment lines.

a. Turn the key switch, but do not start the engine.
b. With the restraint bar down, move the auxiliary hydraulic control back and

forth. This will relieve the pressure in the hydraulic system.

4. With the engine OFF , leave the operato r’s compartment, disconnect the auxil-

iary hydraulic hoses and rotate the latch levers completely vertical to fully
retract the latch pins.

5. Start the engine and be sure that the lift arm is fully lowered and in contact

with the loader frame.

6. Tilt the hitch forward and slowly back the loader away until the attachment is

free from the loader.

Self-Leveling (optional)

The self-leveling feature is intended to automatically keep the attachment level
while the lift arm is being raised. Self-leveling operates only when the lift arm is
raised; when the lift arm is lowered, self-leveling is not activated.

Using a Bucket

Always maintain a safe distance from electric

power lines and avoid contact with any electri­cally charged conductor or gas line. Accidental contact or rupture
can result in electrocution or an explosion. Contact the “Digger’s
Hotline” or proper local authorities for utility line locations before
starting to dig.

Driving over Rough Terrain

When traveling over rough terrain, drive slowly with the bucket lowered.

46 50950260/AP1216

Driving on an Incline

Figure 2 Loading

WARNING

Figure 3 Digging

WARNING

When traveling up or down on an incline, travel with the heavy end pointing
uphill. Try to avoid traveling on an incline, but always travel with the bucket as
possible to maintain stability.

Loading a Bucket

Approach the pile with the lift arm fully
lowered and the bucket tilted slightly for­ward until the edge contacts the ground.
Drive forward, lifting the lift arm and
tilting back the bucket to fill it. Back
away from the pile.

Always carry the loaded bucket with the lift arm

resting on the loader frame. For additional sta­bility when operating on inclines, always travel with the heavier end
of the loader toward the top of the incline.

Digging with a Bucket

Approach the digging site with the lift
arm slightly raised and the bucket tilted
forward until the edge contacts the
ground. Break the ground by driving for­ward and gradually lowering the lift arm.

With the bucket filled, tilt the bucket
back, and back the loader away from the
material. Rest the lift arm against the
loader frame before proceeding to the
dumping area.

Dumping the Load onto a Pile

Carry a loaded bucket as low as possible until reaching the pile. Gradually stop
forward motion and raise the lift arm high enough so that the bucket clears the
top of the pile. Then slowly move the loader ahead, to position the bucket to
dump the material on top of the pile. Empty the bucket and back the loader away
while tilting the bucket back and lowering the lift arm.

Never push the controls into the float position

with the bucket or attachment loaded or raised,
because this will cause the lift arm to lower rapidly.

50950260/AP1216 47

Dumping the Load Into a Box

Figure 4 Dumping Into a Box

WARNING

Figure 5 Scraping

Figure 6 Leveling the Ground

Carry the loaded bucket low and approach
the vehicle or bin. Stop your approach as
close to the side of the box as possible
while allowing for clearance to raise the
lift arm and loaded bucket. Next, raise the
lift arm until the bucket clears the top of
the box and move the loader ahead, to
position the bucket over the inside of the
box, slowly dump the bucket. After the
material is dumped, back away from the
box while tilting the bucket back and low­ering the lift arm.

Dumping the Load Over an Embankment

Do not drive too close to an excavation or
ditch. Be sure the surrounding ground ha s ade-

quate strength to support the weight of the loader and the load.

Carry the loaded bucket as low as possible while traveling to the dumping area.
Stop the loader where the bucket extends half-way over the edge of the embank­ment. Tilt the bucket forward and raise the lift arm to dump the material. After
the material is dumped, back away from the embankment while tilting the bucket
back and lowering the lift arm.

Scraping with a Bucket

For scraping, the loader should be operated
in the forward direction. Position the lift
arm down against the loader frame. Tilt the
bucket cutting edge forward at a slight
angle to the surface to be scraped. While
traveling slowly forward with the bucket in
this position, material can flow over the
cutting edge and collect inside the bucket.

Leveling the Ground

Drive the loader to the far edge of the area
to be leveled. Tilt the bucket forward to
place the bucket cutting edge at a 30 to
45 degree angle to the surface to be
leveled. Then place the lift arm into the
“float” position and drive the loader rear­ward dragging the dirt and, at the same
time, leveling it.

48 50950260/AP1216

Note: The float (detent) position for T-Bar controlled loaders is reached by

WARNING

pushing the right handle all the way forward. For hand/foot controlled loaders,
use your toes to push the front of the left pedal all the way down.

Check that the work area is cl ear o f peo ple and

obstacles. Always look in the direction of
travel.

Vibration Information

Compact construction equipment is generally used in harsh environments. This
type of usage can expose an operator to uncomfortable levels of vibration. It is
useful to understand exposure to vibration levels when operating com pact equip ­ment and what can be done to reduce vibration exposure. As a result, equipment
operation can be more efficient, productive and safe.

An operator’s exposure to vibration occurs in two ways:

 Whole-Body Vibration (WBV)
 Hand-Arm Vibration (HAV)

This section will cover primarily WBV issues, because evaluations have shown
that operation of mobile compact construction equipment on jobsites typically
results in HAV levels less than the allowed exposure limit of 2.5 m/s

Employers in Member States of the European Union must comply with the Phys­ical Agents (vibration) Directive, 2002/44/EC.

Effective control of vibration exposure for an operator involves more than just
vibration levels on the machine. The job site, how the machine is used, and
proper training all play important roles in reducing vibration exposure.

Vibration exposure results from:

2

.

 worksite conditions
 how the machine is operated
 the machine characteristics

Common causes of high WBV vibration levels:

 Using a machine that is improper for the task
 Work site with potholes, ruts and debris
 Improper operating techniques, such as driving too fast
 Incorrect adjustment of the seat and controls
 Other physical activities while using the machine

50950260/AP1216 49

Vibration Measurement and Actions

The vibration directive places the responsibility for compliance on employers.
Actions that should be followed by employers include:

 Assess the levels of vibration exposure.
 Determine from this assessment if operators will be exposed to vibration

levels above the limits stated in the directive.

 Take appropriate actions to reduce operator’s exposure to vibration.
 Provide operators with information and training to reduce their exposure to

vibration.

 Keep good records and update operations and training on a regular basis.

If the assessment concludes that vibration level exposure is too high, one or more
of the following actions may be necessary:

1. Train operators

 Perform operations (accelerating, steering, braking, etc.) in a smooth

manner.

 Adjust machine speed appropriately.
 Adjust the controls, mirrors and seat suspension for comfortable operation.
 Travel across the smoothest parts of the work site and avoid ruts and pot-

holes.

2. Choose proper equipment for the job

 Use machines with the proper power and capacity.
 Select machines with good suspension seats.
 Look for controls that are easy to use.
 Ensure good visibility from the operator’s position.

3. Maintain the work site

 Smooth ruts and fill potholes in traffic areas whenever possible.
 Clean up debris frequently.
 Vary traf fic patterns to avoid ex posure to rough terrain.

4. Maintain the equipment

 Ensure correct tire pressures.
 Check that seat suspension and all controls work smoothly and properly.

Vibration Levels

The following two tables show typical Whole-Body and Hand-Arm Vibration
levels for the Gehl R105 servo-controlled skid-steer loaders with their different
seat options.

50 50950260/AP1216

Servo Whole-Body and Hand-Arm Vibration Levels*

Servo Whole-Body Servo Hand-Arm

Seat Option

Mechanical
Suspension

Vibration

m/s

2

Uncertainty

2

m/s

Vibration

2

m/s

Uncertainty

1.24 0.62 1.80 0.90

m/s

2

Standard

Non-Suspen-

1.12 0.56 1.70 0.85

sion

*Whole-Body Vibration levels in accordance with ISO 2631-1. Hand-Arm Vibration levels in
accordance with ISO 5349-1.

Highway Travel

If it becomes necessary to move the loader a long distance, use a properly rated
trailer. (See “Transporting/Towing the Loader” on page 54.) For short distance
highway travel, attach an SMV (Slow-Moving Vehicle) emblem (purchased
locally) to the back of the loader. For highway operation, install the optional
amber strobe light. Check state and local laws and regulations.

50950260/AP1216 51

Lifting the Loader

WARNING

The loader can be lifted using a single-point or four-point lift kit, which is avail­able from your Gehl dealer.

• Before lifting, check the lift kit for proper installation.

• Never allow riders in the operator’s compartment while the loader is lifted.

• Keep everyone a safe distance away from the loader while it is lifted.

• Loader may only be lifted with an empty bucket or empty pallet forks, or with no
attachment. Never lift the loader with attachments other than those stated.

Lift equipment used and its installation is the responsibility of the party con­ducting the lift. All rigging MUST comply with applicable regulations and
guidelines.

1. Using suitable lift equipment, hook into the lift eyes. Adjust the length of the slings or chains to lift the loader level.

Important: As needed, use a spreader bar to prevent the slings or chains from
rubbing the sides of the ROPS/FOPS. (Four-point lift only)

Note: The loader may be slightly off level (10 degrees max.) when lifted.

2. Center the hoist over the ROPS/FOPS. To prevent shock loading of the equip­ment and excessive swinging, slowly lift the loader off the grou nd. Perform
all movements slowly and gradually. As needed, use a tag line to help posi­tion the loader and keep it from swinging.

Storing the Loader

If the skid-steer loader is to be stored for a period in excess of two months, the
following procedures are suggested:

1. Fully inflate the tires.

2. Lubricate all grease zerks.

3. Check all fluid levels and replenish as necessary. (Review and follow the

engine manufacturers recommendations from the Engine Operator’s Manual.)

4. Add stabilizer to the fuel per the fuel supplier’s recommendations. If the fuel has a mixture of BioDiesel, empty the fuel tank before storing.

5. Turn the electrical battery disconnect switch to its OFF position and remove the battery, charge it fully and store in a cool, dry location.

6. Protect against extreme weather conditions such as moisture, sunlight and temperature.

52 50950260/AP1216

Removing Loader from Storage

1. Check the tire air pressure and inflate the tires if they are low.

2. Connect the battery and check that the electrical battery disconnect switch is

turned to its ON position.

3. Check all fluid levels (engine oil, transmission/hydraulic oil, engine coolant

and any attached implements). (Review and follow the engine manufacturers
recommendations from the Engine Operator’s Manual.)

4. Start the engine. Observe all gauges. If all gauges are functioning properly

and reading normal, move the machine outside.

5. Once outside, park the machine and let the engine idle for at least five min-

utes.

6. Shut the engine off and walk around machine. Make a visual inspection look-

ing for evidence of leaks.

50950260/AP1216 53

Transporting/Towing the Loader

WARNING

Figure 7 Front Tie

Down/Retrieval point

Figure 8 Rear Tie Down/

Retrieval point

Park the truck or trailer on a level surface. Be

sure the vehicle and its ramps have the weight
capacity to support the loader. Make sure the vehicle surface and its
ramps are clear of debris and slippery material that may redu ce trac­tion. Move the loader on and off the vehicle ramp slowly and care­fully. Failure to follow these instructions could result in an overturn
accident. Towing the loader is not recommended as a means of
transportation.

Observe all local regulations governing
the loading and transporting of equipment
(Reference: U.S. Federal Motor Carrier
Safety Regulations, Section 392). Ensure
that the hauling vehicle meets all safety
requirements before loading the skid-steer
loader. Use the tie down/retrieval points
in situations where lifting the loader is not
possible and the overall distance by which
the loader is to be moved is less than 100
feet (30.5 m) at 6 mph (10 km/hr) or less.
The optional brake release package (page

48) facilitates loader retrieval in such situ­ations. When transporting a loader:

1. Block the front and rear of the hauling vehicle’s tires.

2. If the loader has an attachment, lift it slightly off the ground.

3. Back the loader slowly and carefully up the ramp onto the vehicle.

4. Lower the loader attachment to the

vehicle deck, turn off the engine and
remove the key.

5. Fasten the loader to the hauling vehi-

cle at the points indicated by the tie­down decals (Figure 7 and Figure 8).

6. Measure the clearance height of the

loader and hauling vehicle. Post the
clearance height in the cab of the vehi­cle.

When towing a loader:

1. Connect the towline to both tie

down/retrieval points at the front or the rear of the loader. Use of only a single
retrieval point or connecting the towline to any point on the load er other th an
the designated retrieval locations could result in loader damage.

2. The towline strength is at least 1.5 times the gross weight of the loader. The

towline length is such that the maximum towing angle does not exceed 20°.

54 50950260/AP1216

Diesel Particulate Filter (DPF) Regeneration

WARNING

WARNING

Procedures (DPF Models)

The Diesel Particulate Filter (DPF) treats exhaust emissions in compliance with Tier
4 / Stage 3B emission standards. The DPF filter relies on high exhaust temperatures.
Periodic DPF maintenance (regeneration) is required, dependent upon machine
operation load / temperature.

Note: Machines operated primarily at high loads and operating temperatures
require less frequent DPF maintenance. Extended periods of engine idling rap­idly increases DPF soot levels, requiring more frequent regeneration operations.

There are three modes of DPF regeneration:

• Passive / Assist Regeneration: Occurs automatically without operator input.

Passive/assist regeneration does not affect machine operation.

• Reset Regeneration: Occurs automatically, but can be inhibited by the operator.

Increases exhaust gas temperatures. Reset regeneration occurs approximately
every 100 hours of operation. See “Reset Regeneration” on page 56.

Note: Reset regeneration effectiveness is improved if the machine is operated at
mid- to high-throttle settings when reset regeneration mode is in progress.

• Stationary Regeneration: Requires operator action to initiate and takes approxi-

mately 25-30 minutes to complete. See “Stationary Regeneration” on page 57.

Important: The machine cannot be operated and must be parked in a well-ventilated
area away from flammable materials when stationary regeneration is in progress.

There is a possibility of carbon monoxide poisoning if
stationary regeneration occurs in an enclosed space.

Always perform stationary regeneration in a well-ventilated area.

During regeneration, there will be high exhaust gas
temperatures, even at low load. Stay clear of the DPF

during regeneration.

50950260/AP1216 55

Reset Regeneration

1234.5

Figure 9 – Reset Regeneration In-

Progress

K

CAUTION

ok

Figure 10 – Reset Regeneration

Inhibit Button

U

W

Important: Reset regeneration can be prevented from occurring. See “Reset
Regeneration Inhibit” on page 56.

Reset regeneration occurs automatically (unless inhibited) approximately every 100
hours of operation.

Note: Reset regeneration effectiveness
is improved if the machine is operated
at mid- to high-throttle settings while
regeneration is in progress.

When reset regeneration occurs, the DPF
in-progress (elevated temperature)

symbol
screen.

Reset Regeneration Inhibit

DPF regeneration inhibit prevents reset regeneration from occurring.

power and will force premature DPF soot filter replacement.
To temporarily inhibit reset regeneration,

hold down button (U, Figure 10) until the
strikethrough in the Reset Regeneration
symbol (W) turns to red.

(K, Figure 9) displays on the

Permanently inhibiting regeneration is not recommended,

as this will eventually cause significant reduction in engine

Note: DPF in-progress (elevated tem­perature) symbol
not be displayed when reset regenera­tion is inhibited.

(K, Figure 9) will

56 50950260/AP1216

Stationary Regeneration

n/min

Figure 11 – Stationary Regenera-

tion Request Screen

n/min

ok

Figure 12 – Stationary Regenera-

tion

A
B

C

Z

Stationary regeneration may be
periodically required to reduce DPF soot
build-up. The frequency of stationary
regeneration is dependent upon machine
operation and engine load.

The machine cannot be used during
stationary regeneration and cannot be
moved without interrupting the stationary
regeneration process.

When stationary regeneration needs to be
performed, the regeneration request
screen (Figure 11) displays on the
information center electronic display.

Note: The stationary regeneration request screen can be temporarily dismissed
by pressing the reset regeneration inhibit button (U, Figure 10) for 3 seconds.
Until the previous screen displays. The stationary regeneration request screen
will return 1 minute after being dismissed, for as long as the request remains
active.

Important: Perform stationary regeneration as soon as possible when the stationary
regeneration request screen displays. Postponing stationary regeneration for
extended periods will cause significant reduction in engine power and will force
premature DPF filter core replacement.

To proceed with stationary regeneration
(Figure 12):

1. Park the machine in a safe, well­ventilated location away from
flammable materials.

2. The following conditions need to be met before stationary regeneration continues:

A. Press the

control keypad (page 37) or lift
the operator restraint bar to apply

button on the

the parking brake. A checkmark is
displayed next to the parking
brake symbol (A).

B. When engine coolant has reached

operating temperature (above
140° F / 60° C, a checkmark is
displayed next to the coolant temperature symbol (B).

50950260/AP1216 57

C. Place throttle controls to the lowest speed setting. A checkma rk is displayed

22 %

Figure 13 – Stationary Regenera-

tion In-Progress Screen

CAUTION

ok

Figure 14 – Forcing Stationary

Regeneration

Y

X

next to the engine RPM symbol when the engine is running at low idle.

3. When all three checkmarks (A, B & C) are displayed on the Stationary Regeneration screen, press and hold the button (Z) until the Stationary Regeneration In-Progress screen displays (Figure 13).

Note: Stationary regeneration can be
interrupted at any time by releasing the
parking brake, advancing the throttle,
or stopping the engine. Stationary
regeneration must start again from the
beginning if it is interrupted.

Stationary regeneration completion
percentage is displayed as during the stationary regeneration progresses. Progress
percentage disappears when stationary regeneration completes.

Note: Stationary regeneration takes approximately 25-30 minutes.

It is not necessary to stay in the machine during stationary

regeneration. Keep the machine under observation while
regeneration is in progress in case of malfunction. Keep bystanders away from the
machine while regeneration is in progress.

Forcing Stationary Regeneration

Stationary regeneration can be performed at any time after 50 operating hours
following the previous stationary regeneration.

To perform stationary regeneration on­demand:

Press button (Y, Figure 14) associated
with the DPF regeneration symbol (X),
until the regeneration screen displays.
Refer to “Stationary Regeneration” on
page 57 to proceed with stationary
regeneration.

58 50950260/AP1216

DPF Maintenance

Figure 15 – DPF Service Screen

DPF soot filter replacement is required
when the DPF (Diesel Particulate
Filter) Service Screen (Figure 15) dis­plays.

Note: Contact your dealer when the
DPF Service screen displays.

Back-Up Alarm

A back-up alarm system is optionally available which serves to warn people
working in the area around the machine of the machine’s rearward movement.
The back-up alarm is installed within the engine compartment on the inside sur­face of the rear door. The alarm emits a tone whenever the machine begins to
move in the rearward direction.

50950260/AP1216 59

Notes

60 50950260/AP1216

CHAPTER 5

WARNING

12

9

8

10

6

1

2

11

4

7

3

5

Figure 1 Engine Com-

partment - DPF Models

1. Air Cleaner

2. Exhaust Tube

3. Radiator/Cooler

4. Coolant Recovery Tank

5. Hydraulic Oil Filter

6. Engine Oil Dipstick

7. Engine Oil Fill Cap

8. Engine Oil Filter

9. Fuel Filter

10. Fuel Pump

11. Water Trap

12. DPF Cannister

SERVICE

Before servicing the machine, unless expressly
instructed to the contrary, exercise the MAN-

DATORY SAFETY SHUTDOWN PROCEDURE (page 6).
After service has been performed, be sure to restore all guards,

shields and covers to their original positions before resuming
loader operation.

This Service chapter details procedures for performing routine maintenance
checks, adjustments and replacements. Most procedures are referred to in the
Troubleshooting and Maintenance chapters of this manual. Re fer to the Mainte­nance Interval Chart (page 111 ) for ser v ice intervals. Refer to the separate engine
manual for engine-related adjustments, lubrication and service procedures.

Note: All service procedures, except those described under the Dealer Services
topic are owner-operator responsibilities.

Important: Always dispose of waste lubricating oils and hydraulic fluids
according to local regulations or take to a recycling center for disposal. Do not
pour onto the ground or down the drain.

Dealer Services

The following areas of component service, replacement and adjustments require
special tools and knowledge for proper servicing and should be performed only
by your authorized Gehl skid-steer loader dealer: hydrostatic drive components,
hydraulic system pumps, valves, hydraulic cylinders, electrical components
(other than battery, fuses or relays).

50950260/AP1216 61

Tilting Back the ROPS/FOPS

Figure 2 Engine Compartment -

Non-DPF Models

1. Air Cleaner

2. Muffler

3. Radiator/Cooler

4. Coolant Recovery Tank

5. Hydraulic Oil Filter

6. Engine Oil Dipstick

7. Engine Oil Fill Cap

8. Engine Oil Filter

9. Fuel Filter

10. Fuel Pump

11. Water Trap

1

5

2

3

7

6

9

10

4

11

8

Figure 3 ROPS Lock

Mechanism

WARNING

WARNING

For service, unbolt the two anchor bolts at
the front of the ROPS/FOPS and tilt it
back slowly, moving the control handles
out of the way. A gas-charged spring
helps tilt it back. A self-actuating lock
mechanism engages to lock the
ROPS/FOPS in a rolled-back position. To
lower the ROPS/FOPS, apply upward
force on it while pulling the lock mecha­nism handle toward the front of the loader.
Lower the ROPS slowly onto the chassis,
moving the control handles out of the
way. Reinstall the anchor bolts, washers
and locknuts.

Never operate the loader with the ROPS/FOPS

removed or locked back. Be sure the lock is
securely engaged when the ROPS/FOPS is tilted back. Properly sup­port the ROPS/FOPS when unlatching the lock mechanism and low­ering the ROPS/FOPS. Be sure to reinstall the anchor bolts, washers
and locknuts before resuming loader operation.

Loader Raising Procedure

T o raise the skid-steer loader so all four tires are of f the ground, use the procedure
below:

62 50950260/AP1216

Do not rely on a jack or hoist to maintain the

“raised” position without additional blocking

and supports. Serious personal injury could result from improperly

Figure 4 Blocked Loader

raising or blocking the skid-steer loader.

1. Using a jack or hoist capable of lifting the fully-equipped weight of the loader (with all attached options), lift the rear of the loader until the rear tires are off the ground.

2. Stack wooden blocks under the flat part of the loader chassis. They should run parallel with, but not touch, the rear tires (Figure 4).

3. Slowly lower the loader until its weight rests on the blocks. If the tires still touch the ground, raise the loader again, add more blocks and lower again.

4. Repeat Steps 1 through 3 for the front end. When the procedure is finished, all four tires will be off the ground so they can be removed.

Loader Lowering Procedure

When service or adjustment procedures are complete, the skid-steer loader can be
taken down from the “raised” position. To lower the loader ont o it s tires:

1. Using a jack or hoist, raise the front of the loader until its weight no longer rests on the front blocks.

2. Carefully remove the blocking under the front of the loader.

3. Slowly lower the loader until the front tires are resting on the ground.

4. Repeat Steps 1 through 3 for the rear of the loader. When the procedure is finished, all four tires will be on the ground and the blocks removed from under the loader.

Replacement Parts

Part Description Gehl Part No.

Air Cleaner Element, Primary 188814
Air Cleaner Element, Secondary 188817
Hydraulic Oil Filter Element 074830
Engine Oil Filter Element 195568
Fuel Filter Element - DPF Models 50352551
Fuel Separator Element - DPF Models 50352550
Fuel Filter Element - Non-DPF Models 137500
Fuel Separator Element - Non-DPF Models 182130

Note: Part numbers may change. Your Gehl dealer will always have the latest
part numbers.

50950260/AP1216 63

Adjustments

Control Handles

The control handles do not require routine adjustment. Refer to the Service
Manual for the initial setup procedure.

Fuel Sender

The fuel sender, located in the fuel tank, sends a signal to the fuel gauge indi­cating the amount of fuel left in the fuel tank.

Check the fuel sender periodically to ensure that the mounting screws are tight
and that there is no fuel seepage around the gasket. If replacement is required,
apply an RTV or gasket sealant around the gasket when restoring the fuel sender.

Drive Chains

The drive chains do not require routine adjustment. Refer to the Service Manual
for the initial setup procedure.

Removing Foreign Material

The loader should be cleared daily of dirt and other foreign materials in the fol­lowing areas:

• around the lift cylinders

• at the front of the loader

• on the hitch, especially around tilt cylinder

• around the hydraulic oil reservoir breather

• in the engine compartment

• in the operator’s compartment

Important: Build-up of foreign materials in these areas can interfere with the
operation of the loader, cause component da mage or become a fire hazard.

64 50950260/AP1216

Lubrication

Listed below are the locations, temperature ranges and types of recommended
lubricants to be used when servicing this machine. Refer to the separate engi ne
manual for more information regarding recommended engine lub ricants, quanti­ties required and grades.

Hydraulic
System

Chaincase Oil

Grease Fit­tings

Engine Oil

Use Petro Canada HVI60, Mobil DTE 15M or equivalent, which
contain anti-rust, anti-foam and anti-oxidation additives, and
conforms to ISO VG46.
Capacity: 8 U.S. gallons (30,0 liters)

Use SAE grade 10W-30 motor oil.
Capacity (each side):

8 U.S. quarts (7,6 liters)

Use lithium based grease

Important: Refer to the Engine Operator’s Manual for specific
engine oil recommendations.
Service Classification: API-CJ-4 SM
Capacity: 7.6 U.S. quarts (7,2 L)

Refer to the following figure for grease fitting locations. Wipe dirt from the fit­tings before greasing them to prevent contamination. Replace any missing or
damaged fittings. To minimize dirt build-up, avoid excessive greasing.

50950260/AP1216 65

Figure 5 Grease Every 10 Hours (or daily)

1. Lift arm pivots (2)

2. Lift cylinder pivots (4)

3. Tilt cylinder pivots (2)

4. Attachment Bracket pivots (2)

2

4

3

1

66 50950260/AP1216

50/250

250

10

50/500

500

250

Figure 6 Service Locations (see Maintenance Chart on page 97.)

Lubrication Procedure

Check Engine Oil Level (page 70)
Check Hydraulic Oil Level (page 78)
Grease Hitch, Hitch-related Cylinder Pivots

and Latch Pins (page 65)
Grease Lift Arm Pins (page 65)

Check Oil Level in Chaincases (page 80)
Change Engine Oil and Filter (page 71)
Change Hydraulic Oil Filter (page 78)
Change Hydraulic Oil (page 78)
Change Chaincase Oil (page 80)
Check and Drain Water Separator (page 71)
Replace Filter in Water Separator (page 71)

10 Hours
(or Daily)50Hours

250

Hours

500 Hours
(or Yearly)




















 Perform the initial procedure at 50 hours, then at the indicated intervals.

50950260/AP1216 67

Engine Air Cleaner

1

6

4

3

5

2

Figure 7 Dual-Element Air Cleaner -

DPF Models

1. Restriction Indicator

2. Element Housing

3. Elbow Hose

4. Hose Connector

5. Sound Diffuser/Intake Suppressor

6. Air Intake Tube

Figure 8 Dual-Element Air

Cleaner - Non-DPF Models

1. Restriction Indicator

2. Element Housing

3. Inner Filter Element

4. Outer Filter Element

5. Element Cover

6. Dust Ejector

1

2

3

4

5

Important: Failure to follow
proper filter servicing instructions
could result in catastrophic engine
damage.

The air cleaner consists of an outer
(primary) filter element and an
inner (secondary) filter element. An
air filter restriction indicator for
monitoring the condition of the ele­ments is located on the right side of
the front of the air cleaner. If the air
filter becomes restricted, this indi­cator will turn red to warn the
operator that the element(s) require
service. Push the reset button
located on the end of the indicator
after fitting a clean element. For
replacement elements, refer to the
“Replacement Parts” topic
(page 63).

Note: Before replacing the filter
element(s), push the reset button on
the indicator. Start the engine and
adjust the throttle to full speed. If
the indicator does not turn red, do
not replace the element(s).

The outer element should be
replaced only when the restriction
indicator turns red. The inner ele­ment should be replaced every
third time the outer element is
replaced, unless the outer element
is damaged or the inner element is
dirty.

Along with a daily check of the
restriction indicator, check the air
cleaner intake hose and clamps,
and the mounting bracket hardware
to be sure they are properly tightened.

68 50950260/AP1216

Access

1. Open the rear door and engine access cover.

2. Unlatch the clamps on the air cleaner and remove the cover. Clean out any

dirt built up in the cover assembly .

Outer Element

1. Carefully pull the outer element out of the housing. Never remove the inner element unless it is to be replaced.

2. Clean out any dirt built up in the housing. Leave the inner element installed during this step to prevent debris from entering the engine intake manifold.

3. Replace the outer element.

Note: Manitou Americas does not recommend cleaning the outer element.

4. Use a trouble light inside the outer element to inspect for spots, pinholes or ruptures. Replace the outer element if any damage is noted. The outer element must be replaced if it is oil- or soot-laden.

Inner Element

Note: Replace the inner element only if it is dirty or if the outer element has been
replaced three times.

1. Before removing the inner element from the housing, clean out any dirt built
up in the housing. Leave the inner element installed during this step to pre­vent debris from entering the engine intake manifold.

2. Remove the inner element.

Reinstallation

1. Check the inside of the housing for any damage that may interfere with the elements.

2. Be sure that the element sealing surfaces are clean.

3. Insert the element(s), making sure that they are seated properly.

4. Secure the cover to the housing with clamps.

5. Check the hose connections and be sure they are all clamped and tightened

properly.

6. Reset the restriction indicator by pressing the reset button.

50950260/AP1216 69

Engine Service

WARNING

Figure 9 Oil Dipstick

and Fill Cap - DPF Models

1. Oil Dipstick

2. Oil Fill Cap

1

2

Figure 10 Oil Dipstick

and Fill Cap - Non-DPF Models

1. Oil Dipstick

2. Oil Fill Cap

1

2

Check Engine Mounting Hardware

All bolts that secure the engine mounting brackets to the engine and the loader
frame should be checked and re-tightened as necessary.

Allow hot engine and hydraulic system compo­nents to cool before servicing.

Checking Engine Oil Level

Important: For new units, the initial oil
change should be after the first 50 hours.

Open the rear door and engine access
cover. Pull out the dipstick and check the
oil level. Markings on the dipstick repre­sent FULL and LOW (add oil) levels.

Refer to the Maintenance Interval Chart
(page 97) for the service interval for
replacing the engine oil and filter.

70 50950260/AP1216

Changing Engine Oil and Filter

Figure 11 Rear Belly Pan

1. Run the engine until it is at operating temperature. Stop the engine. Remove the rear belly pan.

2. Remove the drai n pl ug.

3. From the engine compartment,

remove the oil filter. Clean the filter
sealing surface.

4. Put clean oil on the new oil filter
gasket. Install the filter and tighten 3/4
of a turn past the point where the gas­ket contacts the filter head.

5. Reinstall and tighten the drain plug.

6. Remove the oil cap and add the rec-

ommended oil. Refer to the “Lubrication” topic in this chapter for oil specifi­cations and capacities.

7. Start the engine and let it run for several minutes at low idle. Stop the engine. Check for leaks at the oil filter, drain plug and remote oil drain hose. Check the oil level. Add oil if it is not at the top mark on the dipstick.

For a replacement element, refer to the “Replacement Parts” topic (page 63).

Changing Fuel Filter

The engine has a fuel filter located on the left side of the engine. To change it:

1. Shut off the fuel supply by turning the fuel shutoff valve on top of the water trap.

2. Non-DPF Models: Shut off the return line by turning the valve on the fuel tank.

3. Remove the fuel filter element.

4. Lubricate new fuel filter element gasket with diesel fuel.

5. Install and tighten the filter element one-half turn past point the where the

gasket contacts the filter head.

6. Turn shutoff valve on water separator to ON.

7. Non-DPF Models: Turn on the fuel supply at the fuel tank.

The engine is self-priming. To remove air before starting, turn the ignition key to
the ON position for 30 seconds.

For a replacement element, refer to the “Replacement Parts” topic (page 63).

50950260/AP1216 71

Servicing Water Separator (DPF Models)

Figure 12 Location of Water

Separator

The water separator is located between
the fuel tank and the main fuel filter and is
used to remove finely dispersed water in
diesel fuel. Check on a daily basis and
drain if necessary. Water can be drained
from the separator by opening the valve
located at the bottom of the separator
bowl.

Important: Water in the fuel system can
cause severe engine damage. Drain water
from the water separator anytime water is
present.

To change the water separator fil ter, turn
the plastic petcock located on top of the water separator a 1/4 turn to stop fuel
flow. Unscrew the separator bowl from the housing and pull down on the existing
filter to release it from the housing. Replace with a new filter and reinstall the
bowl. Return the petcock on the water separator to t he open position. Start the
engine and check for leaks.

Servicing Water Separator (Non-DPF Models)

Periodically check for water in water separator by checking level of float in water
separator bowl. If water is present:

1. Shut off the fuel supply by turning the fuel shutoff valve on top of the water separator.

2. Turn nut to release the bowl from the valve head. Dispose remaining fuel and water.

3. Clean bowl and filter element with warm water until all foreign material is
removed. Replace fuel filter if damaged. Refer to Parts Manual for part num ­ber.

4. Place element onto valve head. Lubricate o-ring on bowl with diesel fuel and place on valve head. Turn nut to tighten.

5. Turn on fuel supply.

Releasing Water from Separator

1. Check red float located in the water separator bowl. If red float is raised, open valve on the bottom of the bowl to drain water.

2. Close valve quickly after float reaches the bottom of the bowl.

72 50950260/AP1216

Spark Arrestor Muffler (Non-DPF Models)

Figure 13 Data Port for

the Engine

Important: The loader is factory-equipped with a spark arrestor type muffler.
Muffler maintenance is required to keep it in working condition. Refer to local
laws and regulations for spark arrestor requirements.

1. Stop the engine, open the rear door and engine cover.

2. Remove the plug from the bottom of the muffler.

3. Block the outlet of the muffler with a non-combustible material.

4. Start the engine and run it for 10-15 seconds.

5. Stop the engine and remove the blockage.

6. Put anti-seize coatin g on the plug.

7. Reinstall and tighten the plug.

Alternator/Fan Belt

Refer to the separate engine manual for setting proper belt tension. If the belt is
worn, cracked or otherwise deteriorated, replace the belt by following the proce­dure in the separate engine manual.

Engine Diagnostic Chart (DPF Models)

When detecting faults, the information
center electronic display (page 37) uses a
diagnostic trouble code (DTC) screen to
alert the operator to the occurrence of the
fault conditions.

The data port for accessing the diagnostic
trouble codes can be found underneath an
electrical cover, right of the seat.

The following pages list descriptions,
diagnostic trouble codes and fault codes
for the engines.

50950260/AP1216 73

Engine Diagnostic Chart (DPF Models)

74 50950260/AP1216

Engine Diagnostic Chart (DPF Models) (cont.)

50950260/AP1216 75

Engine Diagnostic Chart (DPF Models) (cont.)

76 50950260/AP1216

Engine Diagnostic Chart (DPF Models) (end)

50950260/AP1216 77

Hydraulic System

Figure 14 Hydraulic Oil Service

WARNING

Figure 15 Drain Plug

Checking Hydraulic Oil Level

The loader has a dipstick located in the
engine compartment. Check the fluid
level with the lift arm lowered and the
attachment on the ground.

When hydraulic fluid is required, allow
the system to cool. Slowly remove the oil
fill cap, allowing the pressure to dispel
before removing the cap completely.

Add hydraulic fluid as required. Refer to
the Lubrication topic (page 65) for oil
recommendations. Replace the cap.

Changing Hydraulic Oil Filter

Before servicing the hydraulic filter , be sure th e
lift arm is lowered.

1. Open the rear door and engine cover to access the filter. Unscrew the filter.

2. Clean the surface of the filter housing where the element seal contacts the housing. Put clean oil on the rubber gasket of the new filter element.

3. Install and tighten the filter element 3/4 of a turn past the point where the gasket contacts the filter head.

4. For a replacement element, refer to the Replacement Parts topic (page 63).

Changing Hydraulic Oil

The hydraulic oil must be replaced if it becomes contaminated, after major
repairs, and after 1000 hours or one year of use.

1. Remove the oil filler cap.

2. Install a catch pan of sufficient capacity under the oil reservoir (8 gallons [30 liters])

3. Remove the drain plug located on the bottom left of the oil reservoir.

4. Remove and replace the hydraulic oil filter.

5. Reinstall th e drain plug.

6. Refill the reservoir until the oil is between the two lines on the dipstick gauge.

7. Start the engine and operate the hydraulic controls.

8. Stop the engine and check for leaks at the filter and reservoir drain plug.

9. Check the fluid level and add fluid if needed.

78 50950260/AP1216

Cooling Systems

Figure 16 Cooling System

1. Recovery Tank

2. Radiator/Cooler

3. Drain Plug

1

2

3

WARNING

Important: Check the cooling system every day to prevent overheating, loss of
performance or engine damage.

Checking Coolant Level

1. Open the rear door. Check the coolant level in the coolant recovery tank on the inside of the rear door. The coolant recovery tank must be 1/3 to 1/2 full with a cold engine and 2/3 to 3/4 full with a hot engine.

2. Allow the coolant to cool. Do not remove the cap when the coolant is hot. Serious burns may occur.

3. Add premixed coolant, 50% water and 50% ethylene glycol, to the recovery tank if the coolant level is low.

Cleaning Cooling System

1. Park the loader on a level surface, lower the lift arm and stop the engine. Allow the engine to cool.

2. Open the rear door. Lift the engine cover.

3. Clean the radiator and oil cooler by blowing through the fins with high pres-

sure water or air.

Note: The radiator can be tipped out for cleanin g by loosening and rotating the
over-center links on each side. This will also help in cleaning the oil cooler.

Draining/Flushing Cooling System

1. Open the rear door. Lift the engine cover.

2. Slowly remove the radiator cap, allowing pressure to dispel before removing completely.

ator cap, stop the engine and let the system cool. Remove the radiator
cap only after the coolant has cooled. Remove the cap slowly or
severe burns may result.

3. Remove the drai n pl ug and drain the coolant into a suitable container.

4. Replace the drain plug.

Note: Protect the cooling system by adding premixed 50% water and 50% ethy­lene glycol to the system. This mixture will protect the cooling system to -34°F
(-36°C).

50950260/AP1216 79

Liquid cooling systems build up pressure as the
engine becomes hot. Before removing the radi-

5. Fill the radiator fully and the recovery tank half full with the premixed

Figure 17 Check Plug

Figure 18 Right side drain plug

(left side same)

coolant.

6. Reinstall the radiator cap.

7. Run the engine until it is at operating temperature. Stop the engine and let it

cool. Check the coolant level. Add more coolant if required.

Chaincases

The chaincase contains the drive sprockets and drive chains. There are two plugs
in each chaincase. One is to drain the fluid and the other is to check the fluid
level. Refer to the Maintenance Schedule chapter (page 97) for change intervals.
Refer to the Lubrication topic (page 65) for information on oil type and quantity.

Checking and Adding Oil

1. Park the loader on a level surface. Stop the engine.

2. Remove the check plug from each chaincase housing. If the oil can be reached with the tip of your finger, the oil level is adequate.

3. If the level is low, add fluid through the check plug until the oil level reaches the edge of the hole. Reinstall the check plug.

Draining Oil

1. Raise the rear of the machine to aid in draining the chaincases.

2. Remove the drain plug on each chain­case and drain the oil into a suitable
container.

3. Reinstall and tighten the drain plugs.

4. Refill the chaincases at the check

plugs.

Seat and Restraint Bar Switches

Electrical switches in the seat and restraint bar must be closed (operator sitting in
the seat and restraint bar lowered) to complete the circuit and start the engine.

Bucket Cutting Edge

The bucket cutting edge should be replaced when it is worn to within 1in. (25 mm)
of the bucket body.

80 50950260/AP1216

Wheel Nuts

WARNING

Wheel nut torque must be checked before initial operation and every two hours
thereafter until the wheel mounting hardware torque stabilizes at the
recommended setting of 120-130 ft-lbs (161-175 N·m). When tires are removed
and replaced, this procedure must be repeated.

Tires

Rear tires usually wear faster than the front ones. To keep tire wear even, rotate
the tires from front to rear and rear to front.

It is important to keep the same size tire on each side of the loader to prevent
excessive wear on tires or other damage. If different sizes are used, each tire will
be turning at different speeds, causing excessive wear.

The tread bar of all tires must face the same direction.

Mounting Tires

Inflating or servicing tires can be dangerous.

When possible, trained personnel should
service and mount tires. To avoid possible death or serious injury,
follow the safety precautions below.

1. Be sure the rim is clean and free of rust.

2. Lubricate the tire beads and rim flanges with a soap solution. Do not use oil

or grease.

3. Use a clip-on tire chuck with remote hose and gauge, allowing you to stand

clear while inflating the tire. Do not place your fingers on the tire bead or rim
during inflation.

4. Never inflate beyond 35 psi (240 kPa) to seat the beads. If the beads have not

seated by the time the pressure reaches 35 psi (240 kPa), deflate the assembly,
reposition the tire on the rim, lubricate both parts and re-inflate. Inflation
pressure beyond 35 psi (240 kPa) with unseated beads may break the bead or
rim with explosive force sufficient to cause death or serious injury.

5. After seating the beads, adjust the inflation pressure to the recommended

operating pressure.

6. Do not weld, braze or otherwise attempt to repair and use a damaged rim.

50950260/AP1216 81

Checking Tire Pressure

WARNING

WARNING

Tire Size

10 x 16.5 8-ply Heavy-Duty Flotation 60 414
27 x 8.5 –15 8-ply Heavy-Duty 60 414
27 x 10.5 – 15 8-ply Heavy-Duty 60 414

6.5 x 16 – 5.50 Solid Rubber - -

7.00-15 SS Chevron Narrow 8-ply 60 414

Inflation Pressure
psi kPa

Correct tire pressure should be maintained for all tires to enhance operating
stability and extend tire life. Refer to the above chart for the proper inflation
pressure.

When installing tires, be sure they are the same size and style on each side of the
loader. Always replace tires with the same size as the original equipment.

Electrical System

Battery

Before servicing the battery or electrical

system, be sure the battery disconnect switch
(if equipped) is in the “OFF” position. If not equipped with a discon­nect switch, disconnect the ground (-) terminal from battery.

The battery on the loader is a 12-volt, wet-cell battery . To access the battery, open
the rear door and lift the engine cover.

The battery top must be kept clean. Clean it wi th an alkaline solution (ammonia
or baking soda and water). After foaming has stopped, flush the battery top with
clean water. If the terminals and cable connection clamps are corroded or have a
build-up, disconnect the cables and clean the terminals and clamps with the same
alkaline solution.

Explosive gas is produced while a battery is in

use or being charged. Keep flames or sparks
away from the battery area. ALWAYS charge the battery in a well­ventilated area.

Never lay a metal object on top of a battery, because a short circuit
can result.

Battery acid is harmful on contact with skin or fabrics. If acid spills,
follow these first-aid tips:

1. Immediately remove any clothing on wh ic h aci d spills.

82 50950260/AP1216

2. If acid contacts the skin, rinse the affected area with running water for 10 to

Figure 19 Fuse Panels

in the Engine Compartment

Figure 20 Fuse Panel

in the ROPS/FOPS

Compartment

15 minutes.

3. If acid contacts the eyes, flood the eyes with running water for 10 to 15 min-

utes. See a doctor at once. Never use any medication or eye drops unless pre­scribed by the doctor.

4. To neutralize acid spilled on the floor, use one of the following mixtures:

a. 1 pound (0.5 kg) of baking soda in 1 gallon (4 L) of water
b. 1 pint (0.5 L) of household ammonia in 1 gallon (4 L) of water

Whenever the battery is removed, be sure to disconnect the nega­tive (-) battery terminal connection first.

Fuse Panels (DPF Models)

The fuse panels are located in the engine
compartment near the chassis right riser
and behind a panel in the ROPS/FOPS at
the operator’s right elbow area. The
plastic covers are etched with the type of
fuses and relays that can be found under
that particular fuse cover.

50950260/AP1216 83

Fuse Panels (Non-DPF Models)

The are no fuse panels located in the engine compartment or in the ROPS/FOPS
at the operator’s right elbow area. However, three relays can be found behind a
panel in the FOPS/FOPS at the operator’s right elbow area.

84 50950260/AP1216

TROUBLESHOOTING

Electrical System

Problem Possible Cause Corrective Action

Electrical system does
not function

Control pad and
information center
display do not activate
with ignition keyswitch in
the ON/RUN position

Starter does not engage
when ignition keyswitch
turned to the START
position

CHAPTER 6

Battery disconnect switch is in
OFF position.

Battery terminals or cables
loose or corroded.

Battery malfunction.

Blown main fuse.
Main wiring harness connectors

at rear of ROPS/FOPS not
properly plugged in.

Blown fuse. Check circuit and replace fuse.
Battery terminals/cables

loose/corroded.
Main wiring harness connectors

at rear of ROPS/FOPS not
properly plugged in.

Poor electrical connections in
start circuit.

Battery terminals/cables
loose/corroded.

Starter relay malfunction.
Battery

discharged/malfunctioning.
Starter solenoid malfunction. Contact dealer.
Starter or pinion malfunctioning. Repair/replace as needed.
Ignition wiring, seat switch,

restraint bar switch, etc. loose
or disconnected.

Restraint bar raised. Lower restraint bar.
Engine fault code(s). Contact dealer.

Turn battery disconnect switch
to the ON position.

Clean battery terminals and
cables and retighten.

Test battery. Recharge/
replace as necessary.

Correct over-current problem
and replace main fuse.

Check main harness
connectors. Reconnect/repair
as needed.

Clean battery terminals and
cables and tighten.

Check main harness
connectors. Reconnect/repair
as needed.

Check connections repair as
necessary.

Clean battery terminals and
cables and tighten.

T est relay; replace if necessary .
Contact dealer.

Test battery. Recharge/
replace if necessary.

Check wiring for poor
connections, broken leads;
repair wiring or connection.

50950260/AP1216 85

Electrical System

Problem Possible Cause Corrective Action

Fuel gauge inoperative

Coolant temperature
gauge inoperative

Hour meter inoperative

Work/road lights
inoperative

Lift/tilt and/or drive lock
solenoid malfunction

Fuel level sender malfunction. Replace fuel level sender.

Loose wiring/terminal

connections.

Blown fuse. Check circuit and replace fuse.

Fuel gage malfunction. Replace gauge.

Temperature sender

malfunction.

Loose wiring/terminal

connections.

Blown fuse. Check circuit and replace fuse.

Coolant temperature gage

malfunction.

Loose wiring/terminal

connections.

Alternator malfunction. Repair/replace alternator.

Hour meter malfunction.

Single light not working— light

bulb burned out, faulty wiring.

No lights—blown fuse. Check circuit and replace fuse.

Light switch malfunction, poor

ground or other wiring

connection.

Solenoid wiring disconnected or

faulty.

Seat or restraint bar switch

malfunction.

Check wiring connections.

Replace temperature sender.

Check wiring connections.

Replace gauge.

Check wiring/connections.

Replace information center
electronic display.

Check and replace light bulb as
needed, check wiring
connections.

Check ground/wire
connections, replace light
switch.

Check circuit; repair as
necessary.

Contact dealer.

86 50950260/AP1216

Engine

Problem Possible Cause Corrective Action

Engine does not turn
over

Engine turns over but will
not start

Blown fuse. Check circuit and replace fuse.
Dead battery. Charge or replace battery.

Battery disconnect switch in
open position or malfunctioning.

Starter malfunction. Contact dealer.

Operator not in operator’s seat.

Malfunctioning seat/restraint
bar/door switch.

Cab door open (if equipped). Close cab door.
Engine electronics logic error. Contact dealer.
Engine fault code(s) displayed. Identify problem and correct.

Engine cranking speed too
slow.

Fuel tank empty.
Fuel filter plugged or restricted. Change fuel filter.

Fuel paraffin separation in
winter.

Fuel line leak.

Fuel shut-off solenoid not
energizing. (interim Tier 4
engines only)

Fuel filter restricted/fuel hose
restriction.

Fuel pump malfunction. Contact dealer.
Water in fuel filter. Purge water from filter.
Fuel valve on water separator

in the OFF position.
Engine fault code(s) displayed. Identify problem and correct.

Place battery disconnect switch
into closed position— Repair or
replace if necessary.

Operator’s seat must be
occupied. for the engine to
start.

Replace seat/restraint bar/door
switch.

Check battery and
charge/replace as necessary—
tighten battery terminals.

In cold temperatures, pre-warm
the engine.

Fill tank and vent fuel system if
necessary.

Use winter grade diesel fuel.
Tighten all threaded

connections and clamps;
replace fuel line as necessary.

Check electrical
connections/voltage to shut-off
solenoid.

Replace filter/check for pinched
fuel hose.

Turn the valve to the ON
position.

50950260/AP1216 87

Engine

Problem Possible Cause Corrective Action

Engine overheating

Pre-heating module

Engine too cold/ambient

temperature too low.

Crankcase oil level incorrect. Adjust oil level.

Cooling air circulation

restricted.

Fan shroud improperly

positioned.

Improper oil grade or oil

excessively dirty.

Exhaust restricted.

Air filter restricted. Replace filter(s).

Low coolant level. Top off coolant.

Loose fan belt. Tighten fan belt.

Dirty/restricted radiator. Clean radiator.

Thermostat malfunction. Replace thermostat.

malfunction; check connection
and voltage and charge/replace
as necessary. Install block
heater.

With engine off, remove
restriction.

With engine off, reposition
shroud/contact dealer.

Change engine oil.
Allow exhaust to cool; remove

restriction.

88 50950260/AP1216

Engine

Problem Possible Cause Corrective Action

Engine overheating

Crankcase oil level incorrect. Adjust oil level.
Cooling air circulation

restricted.
Fan shroud improperly

positioned.
Improper oil grade or oil

excessively dirty.
Exhaust restricted.
Air filter restricted. Replace filter(s).

Low coolant level. Top off coolant.
Loose fan belt. Tighten fan belt.
Dirty/restricted radiator. Clean radiator.
Thermostat malfunction. Replace thermostat.

With engine off, remove
restriction.

With engine off, reposition
shroud/contact dealer.

Change engine oil.
Allow exhaust to cool; remove

restriction.

50950260/AP1216 89

Engine

Problem Possible Cause Corrective Action

Exhaust excessively
smoky

Black smoke

Blue smoke

White smoke

Black smoke indicates poor and
incomplete diesel fuel
combustion, which could be
caused by:

• Incorrect timing.

• Dirty or worn injectors.

• Incorrect valve clearance.

• Incorrect air/fuel ratio.

• Low cylinder compression.

• Dirty air cleaner.

• Restricted induction syste m.

• Faulty engine tuning.

• Poor quality fuel.

• Carbon build-up in
combustion and exhaust
spaces.

• Cool operating temperatures.

Blue smoke indicates engine oil
combustion, which could be
caused by:

• Worn valve guides or seals.

• Wear in cylinders, piston
rings, ring grooves, etc.

• Cylinder glaze.

• Sticking piston ring.

• Incorrect engine oil grade.

• Fuel dilution in engine oil.

White smoke indicates
incomplete diesel combustion,
or coolant in the combustion
chamber, which could be
caused by:

• Faulty or damaged injectors.

• Incorrect injection timing.

• Low cylinder compression.

• Faulty head gaskets.

• Cracked cylinder
heads/blocks.

90 50950260/AP1216

Hydrostatic System

Problem Possible Cause Reme dy

No response from
either hydrostatic
drive or the lift/tilt
systems.

Traction drive will not
operate in either
direction.

Sluggish response
to acceleration.

Hydraulic oil viscosity is too
heavy.

Hydraulic oil supply is too
low.

Drive coupling failure. Replace the coupling.
Parking brake is engaged. Disengage parking brake.
Hydraulic oil supply is low. Check for low oil level in

Control rod linkage
disconnected.

Low or no charge pressure. Contact your dealer.
Hydrostatic pump(s) relief

valves are malfunctioning.
Air in hydraulic system. Cycle lift and tilt cylinders to

Automatic parking brake
partially engaged.

Hydraulic oil supply is too
low.

Low hydrostatic system
charge pressure.

Drive motor(s) or hydrostatic
pump(s) have internal
damage or leakage.

Allow longer warm-up or
replace existing oil with the
proper viscosity oil.

Check for low oil level in
reservoir. Add oil.

reservoir. Add oil.
Check linkage connection at

control levers and neutral
centering mechanisms.
Reconnect linkage.

Contact your dealer.

maximum stroke and
maintain pressure for a short
time to clear air from system.
Also check for low oil level in
reservoir, fill as needed.

Contact your dealer.

Check for low oil level in
reservoir. Add oil.

Contact your dealer.

Contact your dealer.

50950260/AP1216 91

Hydrostatic System

Problem Possible Cause Reme dy

Hydrostatic drive
is overheating.

Drive system overloaded
continuously.

Lift/tilt or auxiliary system
overloaded continuously.

Drive motor(s) or hydrostatic
pump(s) have internal
damage or leakage.

Oil cooler fins plugged with
debris.

Loader being operated in a
high temperature area with
no air circulation.

Improve efficiency of
operation.

Improve efficiency of
operation.

Contact your dealer.

Clean oil cooler fins.

Reduce duty cycle; improve
air circulation.

92 50950260/AP1216

Hydrostatic System

Problem Possible Cause Reme dy

Hydrostatic (drive)
system is noisy.

Right side doesn’t
drive in either
direction. Left side
operates normally.

Right side doesn’t
drive in forward
direction.

Left side doesn’t
drive in either
direction. Right side
operates normally.

Left side doesn’t
drive in one
direction.

Hydraulic oil viscosity is too
heavy.

Air in hydraulic system. Cycle lift and tilt cylinders to

Drive motor(s) or hydrostatic
pump(s) have internal
damage or leakage.

Rear hydrostatic pump arm
control shaft key missing.

Relief valves on rear
hydrostatic pump
malfunctioning.

Control rod linkage to rear
hydrostatic pump
disconnected.

Relief valve on rear
hydrostatic pump is
malfunctioning.

Rear hydrostatic pump
malfunctioning.

Key missing on front
hydrostatic pump arm control
shaft.

Relief valves on front
hydrostatic pump
malfunctioning.

Control rod linkage to front
hydrostatic pump
disconnected.

Relief valve on front
hydrostatic pump is
malfunctioning.

Front hydrostatic pump
malfunctioning.

Allow longer warm-up or
replace existing oil with the
proper viscosity oil.

maximum stroke and
maintain pressure for a short
time to clear air from system.
Also check for low oil level in
reservoir, fill as needed.

Contact your dealer.

Contact your dealer.

Contact your dealer.

Attach control rod linkage.

Contact your dealer.

Contact your dealer.

Contact your dealer.

Contact your dealer.

Attach control rod linkage.

Contact your dealer.

Contact your dealer.

50950260/AP1216 93

Hydraulic System

Problem Possible Cause Reme dy

Lift/Tilt controls
fail to respond.

Auxiliary hydraulics
do not function.

Hydraulic cylinder
action is slow for lift
and/or tilt functions.

Hydraulic oil viscosity is too
heavy.

Hydraulic oil level is low. Check oil level in reservoir . If

Solenoid valve(s)
malfunctioning.

Restraint bar or seat switch
malfunction.

Restraint bar is raised. Lower the restraint bar.
Lock solenoid malfunctioning Check electrical connections

Restraint bar switch
malfunctioning.

Low engine speed. Operate engine at higher

Hydraulic oil viscosity is too
heavy.

Control linkage is restricted. Check for control linkage

Hydraulic oil leaking past
cylinder piston seals.

Worn gear pump. Contact your dealer.
Solenoid valve(s) could be

malfunctioning.

Relief valve in control valve
not functioning correctly.
(Squealing noise should be
evident while operating.)

Allow longer warm-up or
replace with proper viscosity
oil.

oil is low, check for an
external leak. Repair and add
oil.

Check electrical connections
to lift solenoid and repair.

Check switches.

to lock solenoid and repair
connections as needed. If
lock solenoid is still not
functioning properly, contact
your dealer.

Check electrical connections
to restraint bar switch and
repair connections as
needed. If switch is still not
functioning properly, contact
your dealer.

speed.
Allow longer warm-up or

replace existing oil with
proper viscosity oil.

restriction and adjust.
Contact your dealer.

Check electrical connections
to lift solenoid and repair
connections as needed. If lift
solenoid valve is still not
functioning properly, contact
your dealer.

Contact your dealer.

94 50950260/AP1216

Hydraulic System

Problem Possible Cause Reme dy

Bucket does not level
on the lift cycle.

Jerky lift arm and
bucket action.

Bucket drifts
downward with tilt
control in neutral.

No down pressure
on the bucket.

Bucket will not tilt, lift
arms work properly.

Slow or no response
for bucket tilt, lift
works properly
(Hand/Foot units
only).

Self-leveling valve
misadjusted or
malfunctioning.

Seat or restraint bar switch
malfunction.

Air in the hydraulic system. Cycle lift/tilt cylinders to

Oil in hydraulic reservoir is
low.

Oil leaking past tilt cylinder
seals (internal or external).

Self-leveling valve is
malfunctioning.

Leaking hydraulic hoses,
tubes, or fittings between
control valve and cylinders.

Control valve in float
position.

Tilt cylinders are
malfunctioning.

Relief valve in control valve
not functioning properly.
(Squealing noise should be
evident while operating.)

Tilt solenoid valve
malfunctioning.

Tilt spool in control valve not
actuated or leaking.

Pilot control lines have air in
them.

Low charge pressure. Contact your dealer.
Linkage misadjusted

between right foot pedal and
pilot valve.

Contact your dealer.

Check electrical connections
to the switches. Replace as
needed.

maximum stroke and
maintain pressure for short
time to clear air from system.

Check and add oil.

Contact your dealer.

Contact your dealer.

Inspect hoses and tubes,
tighten fittings. Replace
hoses or tubes as needed.

Take control out of float
position.

Contact your dealer.

Contact your dealer.

Check electrical connections
to tilt solenoid and repair
connections as needed. If tilt
solenoid valves are still not
functioning properly, contact
your dealer.

Check valve control linkage
and/or tube connections to
valve.

Bleed the pilot control line
from the main control valve.

Readjust for full travel
without restriction.

50950260/AP1216 95

Hydraulic System

Problem Possible Cause Reme dy

Lift arm does not
raise, bucket tilt

works properly.

Lift arm doesn’t
maintain raised
position with lift
control in NEUTRAL.

Lift arm will not lower
or raise.

Lift solenoid valve could be
malfunctioning.

Lift spool in control valve not
actuated or leaking.

Oil leading past lift cylinder
seals (internal or external).

Oil leaking past lift spool in
control valve.

Self-leveling valve
malfunctioning.

Leaking hydraulic hoses,
tubes or fittings between
control valve and cylinders.

Lift arm support device
engaged.

Lift solenoid valve
malfunctioning.

Restraint bar not lowered. Lower restraint bar.
Seat or restraint bar switch

malfunction.

Check electrical connections
to lift solenoid and repair
connections as needed. If lift
solenoid valve is still not
functioning properly, contact
your dealer.

Contact your dealer.

Contact your dealer.

Contact your dealer.

Contact your dealer.

Inspect hoses and tubes,
tighten fittings as needed.
Replace as needed.

Raise lift arm and disengage
support device.

Check electrical connections
to solenoid. Repair or replace
as needed.

Check electrical connections
to the switch. Replace switch
as needed.

96 50950260/AP1216